Chicago Electric Grinder 67648 User Manual

7” Angle grinder  
Model 67648  
Set up And OperAting inStructiOnS  
(Grinding Wheel Sold Separately)  
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 2010 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.  
 
nOtice is used to  
address practices not  
SAVe thiS MAnuAl  
Keep this manual for the safety warnings  
and precautions, assembly, operating,  
inspection, maintenance and cleaning  
procedures. Write the product’s serial number  
in the back of the manual near the assembly  
diagram (or month and year of purchase if  
product has no number). Keep this manual  
and the receipt in a safe and dry place for  
future reference.  
related to personal injury.  
cAutiOn, without the  
safety alert symbol, is  
used to address practices not  
related to personal injury.  
general power tool Safety warnings  
wArning read all safety warnings  
and instructions. Failure to follow the  
warnings and instructions may result  
in electric shock, fire and/or serious  
injury.  
Save all warnings and instructions  
for future reference.  
The term ″power tool″ in the warnings  
refers to your mains-operated (corded)  
power tool.  
iMpOrtAnt SAFetY  
inFOrMAtiOn  
in this manual, on the labeling, and  
all other information provided with  
this product:  
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.  
1. work area safety  
a.Keep work area clean and well lit.  
Cluttered or dark areas invite accidents.  
b.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.  
dAnger indicates a  
hazardous situation  
which, if not avoided, will result  
in death or serious injury.  
c.Keep children and bystanders  
away while operating a power tool.  
Distractions can cause you to lose  
control.  
wArning indicates a  
hazardous situation  
which, if not avoided, could  
result in death or serious injury.  
2. electrical safety  
a.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.  
cAutiOn, used with  
the safety alert  
symbol, indicates a hazardous  
situation which, if not avoided,  
could result in minor or moderate  
injury.  
b.Avoid body contact with grounded  
surfaces such as pipes, radiators,  
ranges and refrigerators. There is an  
SKU 67648  
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Page 3  
 
increased risk of electric shock if your  
body is grounded.  
energizing power tools that have the  
switch on invites accidents.  
c.do not expose power tools to rain or  
wet conditions. Water entering a power  
tool will 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 attached to a  
rotating part of the power tool may result  
in personal injury.  
d.do not abuse the cord. never use  
the cord for carrying, pulling or  
e.do not overreach. Keep proper  
footing and balance at all times. This  
enables better control of the power tool  
in unexpected situations.  
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.  
f. dress properly. do not wear loose  
clothing or jewelry. Keep your hair,  
clothing and gloves away from  
e.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.  
moving parts. Loose clothes, jewelry or  
long hair can be caught in moving parts.  
g.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.  
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.  
h.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.  
3. personal safety  
a.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.  
4. power tool use and care  
b.use safety equipment. Always wear  
eye protection. Safety equipment such  
as a dust mask, non-skid safety shoes,  
a hard hat, or hearing protection used  
for appropriate conditions will reduce  
personal injuries.  
a.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.  
b.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.  
c.prevent unintentional starting. ensure  
the switch is in the off-position before  
connecting to power source, picking  
up or carrying the tool. Carrying power  
tools with your finger on the switch or  
c.disconnect the plug from the power  
source and/or the battery pack from  
Page 4  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
the power tool before making any  
adjustments, changing accessories,  
or storing power tools. Such  
preventive safety measures reduce  
the risk of starting the power tool  
accidentally.  
instructions listed below may result in  
electric shock, fire and/or serious injury.  
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.  
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 operate the  
power tool. Power tools are dangerous  
in the hands of untrained users.  
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.  
e.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.  
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.  
f. use the power tool, accessories and  
tool bits etc. in accordance with these  
instructions, taking into account the  
working conditions and the work to  
be performed. Use of the power tool for  
operations different from those intended  
could result in a hazardous situation.  
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.  
5. Service  
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.  
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.  
Safety warnings common  
for grinding, Sanding, and  
wirebrushing Operations  
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  
1. this power tool is intended to  
function as a grinder, sander, or  
wire brushing tool. read all safety  
warnings, instructions, illustrations  
and specifications provided with  
this power tool. Failure to follow all  
SKU 67648  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
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.  
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 accessory may grab  
the surface and pull the power tool out of  
your control.  
13. do not run the power tool while  
carrying it at your side. Accidental  
contact with the spinning accessory  
could snag your clothing, pulling the  
accessory into your body.  
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 work piece  
fragments. the eye protection must  
be capable of stopping flying debris  
generated by various operations.  
The eye protection must be capable  
of stopping flying debris generated by  
various operations. The dust mask or  
respirator must be capable of filtering out  
particles generated by your operation.  
Prolonged exposure to high intensity  
noise may cause hearing loss.  
14. regularly clean the power tool’s air  
vents. The motor’s fan will draw the  
dust inside the housing and excessive  
accumulation of powdered metal may  
cause electrical hazards.  
15. do not operate the power tool near  
flammable materials. Sparks could  
ignite these materials.  
16. do not use accessories that require  
liquid coolants. Using water or other  
liquid coolants may result in electrocution  
or shock.  
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.  
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.  
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  
may make exposed metal parts of the  
power tool ″live″ and shock the operator.  
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 leaving.  
11. position the cord clear of the spinning  
accessory. If you lose control, the cord  
may be cut or snagged and your hand  
Page 6  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
21. This product is not a toy. Keep it out of  
reach of children.  
other reproductive harm. Wash hands  
after handling. (California Health &  
Safety Code § 25249.5, et seq.)  
22. 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:  
25. 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.  
• Avoid operating alone.  
• Do not use with power switch locked  
on.  
• Properly maintain and inspect to avoid  
electrical shock.  
Kickback and related warnings  
• Any power cord must be properly  
grounded. Ground Fault Circuit  
Interrupter (GFCI) should also be  
implemented – it prevents sustained  
electrical shock.  
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.  
23. WARNING: Some dust created by power  
sanding, sawing, grinding, drilling, and  
other construction activities, contains  
chemicals known [to the State of  
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.  
California] to cause cancer, birth defects  
or other reproductive harm. Some  
examples of these chemicals are:  
• Lead from lead-based paints  
• Crystalline silica from bricks and  
cement or other masonry products  
• 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. (California Health  
& Safety Code § 25249.5, et seq.)  
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. The operator can control  
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  
SKU 67648  
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Page 7  
 
torque reactions or kickback forces, if  
proper precautions are taken.  
4. use only wheel types that are  
recommended for your power tool  
and the specific guard designed for  
the selected wheel. Wheels for which  
the power tool was not designed cannot  
be adequately guarded and are unsafe.  
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. Kickback will  
propel the tool in direction opposite to  
the wheel’s movement at the point of  
snagging.  
5. the guard must be securely attached  
to the power tool and positioned for  
maximum safety, so the least amount  
of wheel is exposed towards the  
operator. The guard helps to protect  
operator from broken wheel fragments  
and accidental contact with wheel.  
4. use special care when working  
corners, sharp edges etc. Avoid  
bouncing and snagging the  
6. wheels must be used only for  
recommended applications. For  
example: do not grind with the side of  
cut-off wheel. Abrasive cut-off wheels  
are intended for peripheral grinding,  
side forces applied to these wheels may  
cause them to shatter.  
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.  
7. 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.  
Safety Warnings Specific for  
grinding Operations  
Flanges for cut-off wheels may be  
different from grinding wheel flanges.  
1. Always use proper guard with  
grinding wheel. A guard protects  
operator from broken wheel fragments.  
8. 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.  
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.  
9. dress appropriately. Wear leather  
leggings and fire resistant footwear  
during use. Do not wear pants with cuffs,  
shirts with open pockets, or any clothing  
that can catch and hold molten metal or  
sparks.  
3. hold tool by insulated gripping  
surfaces when performing an  
operation where the 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.  
Page 8  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
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.  
Safety Warnings Specific for  
Sanding Operations  
do not use excessively oversized  
sanding disc paper. Follow  
manufacturer’s recommendations  
when selecting sanding paper. Larger  
sanding paper extending beyond the  
sanding pad presents a laceration  
hazard and may cause snagging, tearing  
of the disc or kickback.  
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.  
Safety Warnings Specific for Wire  
4. Use tools with the lowest vibration when  
there is a choice between different  
processes.  
brushing Operations  
1. be aware that wire bristles are thrown  
by the brush even during ordinary  
operation. do not overstress the  
wires by applying excessive load to  
the brush. The wire bristles can easily  
penetrate light clothing and/or skin.  
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.  
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. Wire wheel or  
brush may expand in diameter due to  
work load and centrifugal forces.  
7. To reduce vibration, maintain the tool  
as explained in this manual. If any  
abnormal vibration occurs, stop use  
immediately.  
SAVe theSe  
inStructiOnS.  
Vibration Safety  
This tool vibrates during use. Repeated  
or long-term exposure to vibration may cause  
temporary or permanent physical injury,  
grOunding  
particularly to the hands, arms and shoulders.  
To reduce the risk of vibration-related injury:  
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 remove the grounding  
prong from the plug. do not use  
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  
SKU 67648  
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Page 9  
 
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  
illustration. (See 3-prong plug and  
Outlet.)  
double insulated tools: tools with  
two prong plugs  
electrician.  
grounded tools: tools with three  
prong plugs  
Outlets for 2-prong plug  
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  
Laboratories, Inc., the Canadian  
3-prong plug and Outlet  
1. Tools marked with “Grounding Required”  
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.)  
Standard Association, and the National  
Electrical Code.  
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.)  
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. 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.  
(See 3-prong plug and Outlet.)  
2. As the distance from the supply outlet  
increases, you must use a heavier gauge  
extension cord. Using extension cords  
with inadequately sized wire causes a  
serious drop in voltage, resulting in loss  
of power and possible tool damage.  
(See table A.)  
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  
3. The smaller the gauge number of the  
wire, the greater the capacity of the cord.  
For example, a 14 gauge cord can carry  
Page 10  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
a higher current than a 16 gauge cord.  
(See table A.)  
Symbology  
Double Insulated  
4. When using more than one extension  
cord to make up the total length, make  
sure each cord contains at least the  
minimum wire size required. (See table  
A.)  
Canadian Standards Association  
Underwriters Laboratories, Inc.  
Volts Alternating Current  
Amperes  
5. 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.)  
V~  
A
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
6. 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.  
7. Make sure the extension cord is properly  
wired and in good electrical condition.  
Always replace a damaged extension  
cord or have it repaired by a qualified  
electrician before using it.  
8. Protect the extension cords from sharp  
objects, excessive heat, and damp or  
wet areas.  
recOMMended MiniMuM wire gAuge  
FOr extenSiOn cOrdS* (120/240 VOlt)  
extenSiOn cOrd  
nAMeplAte  
length  
AMpereS  
(at full load)  
25’ 50’ 75’ 100’ 150’  
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  
SKU 67648  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
SpeciFicAtiOnS  
inStructiOnS FOr putting  
intO uSe  
Electrical Input  
120 V~ / 60 Hz / 11 A  
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.  
Motor No Load Speed  
7,800 RPM  
7”  
Max. Accessory  
Diameter  
Arbor Hole Diameter  
Spindle Thread  
7/8”  
5/8” x 11 TPI  
95gA  
e194601  
tO preVent  
SeriOuS injurY  
FrOM AccidentAl  
This angle grinder can be used for  
grinding steel, stone or ceramic  
OperAtiOn:  
workpieces such as pipe, iron steel  
bar, household bricks and tiles. Do not  
attempt to grind wood or a soft metal  
such as lead. The material will quickly fill  
the disc and render it useless.  
turn the power Switch of the tool  
off and unplug the tool from its  
electrical outlet before  
assembling or making any  
adjustments to the tool.  
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, make sure that the  
item is intact and undamaged. If any parts  
are missing or broken, please call Harbor  
Freight Tools at 1-800-444-3353 as soon as  
possible.  
components  
Spindle Lock  
Button (21)  
Lock-on  
Switch (46)  
Grinding Wheel  
Carbon Brush  
Cap (41)  
(Sold Separately)  
Handle  
(43)  
Trigger  
(47)  
Wheel Guard (3)  
Hex Wrench  
(55)  
Spanner (53)  
Auxiliary Handle (23)  
Figure 1  
Page 12  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
installing the Auxiliary handle  
tO preVent  
Assembly  
installing the wheel guard  
SeriOuS injurY:  
do not operate this tool with one  
hand only or without the  
Auxiliary handle properly  
installed.  
tO preVent  
SeriOuS injurY:  
do not operate this tool without  
the wheel guard properly  
installed.  
Auxiliary Handle locations  
1
Wheel Guard (3)  
2
Figure 2  
1. The Auxiliary Handle (23) may be  
installed in one of three positions,  
on either side or on top of the Gear  
Housing.  
3
Socket Head  
Hex Wrench  
Bolt (4)  
(55)  
Gear Housing Rim  
Figure 2  
2. Screw the threaded end of the Auxiliary  
Handle into the selected position.  
1. Using the Hex Wrench (55), loosen the  
Socket Head Bolt (4) and slide the collar  
of the Wheel Guard (3) over the rim of  
the Gear Housing.  
Tighten securely before beginning work.  
2. Rotate the Wheel Guard as needed to  
shield you during the planned work.  
3. Use the Hex Wrench (55) to tighten  
the Socket Head Bolt securely. Check  
the Wheel Guard to ensure it is firmly  
in place. Adjust if necessary before  
proceeding.  
SKU 67648  
For technical questions, please call 1-800-444-3353.  
Page 13  
 
2. Press in and hold the Spindle Lock  
Button (21) to prevent the Spindle (6)  
from turning.  
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.  
3. Remove the Outer Flange (1). Keep  
the Inner Flange (2) in position on the  
Spindle.  
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:  
tool Set up  
tO preVent  
SeriOuS injurY  
FrOM AccidentAl  
a. Suspend wheel using a pin or finger  
through the arbor hole.  
OperAtiOn:  
45°  
45°  
turn the power Switch of the tool  
off and unplug the tool from its  
electrical outlet before installing  
accessories.  
V
e
r
t
i
c
A
l
hang  
wheel  
from  
pin  
do not install a circular saw  
blade, a wood carving blade,  
carving disc with saw chain  
cutters, or a cutting-carving disc  
on this tool.  
tap  
wheel  
here  
c
e
n
t
e
r
each accessory must have the  
correct arbor size and must fit  
properly on the shoulder  
bushing. Make sure accessories  
are tightened down securely.  
45°  
45°  
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 Illustration).  
installing the grinding wheel  
1. The Grinding Wheel (Sold separately)  
MUST be:  
c. Rotate the wheel 90° and repeat the  
test until the entire wheel has been  
checked.  
rated to at least 8,000 RPM.  
no larger than 7” in diameter.  
• fitted with a 7/8” round arbor hole.  
• 1/4” thick or less.  
suitable for surface grinding, not edge  
grinding.  
d. An undamaged wheel will give a clear  
tone. If cracked, there will be a dead  
sound and not a clear ring.  
dry and clean.  
proven undamaged by inspection and  
by the ring-test explained following.  
5. For wheels with paper gaskets (blotters)  
or metal gaskets: Slip the grinding wheel  
onto the Spindle with the gasket first.  
The gasket should be centered on the  
grinding wheel and the wheel and gasket  
Page 14  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
should rest flat against the Inner Flange.  
wArning: to prevent serious  
injury, gaskets must be used for all  
grinding wheels they are provided  
with. gaskets help prevent grinding  
wheel damage and wheel slippage,  
causes of wheel failure.  
general Operating instructions  
tO preVent  
SeriOuS injurY:  
Grip the tool firmly in both  
hands.  
1. Press and release the Trigger to make  
sure the Trigger is not locked in the on  
position.  
6. Thread the Outer Flange clockwise onto  
the Spindle. Using the Spanner (53)  
tighten only enough so that the wheel is  
securely held on the spindle.  
2. Plug the Cord (52) into the electrical  
outlet.  
wArning: to prevent serious  
injury, do not overtighten flange.  
Overtightening can damage the wheel,  
causing wheel failure.  
3. Hold the Handle (43) with one hand  
and the Auxiliary Handle (23) with your  
other hand. Always use two hands when  
operating this tool.  
work piece and work Area Set up  
4. To start the motor, press and hold the  
Trigger (47), then press and hold the  
Lock-on Switch (46). Release the Trigger  
then the Lock-on Switch. The motor will  
be locked on.  
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.  
5. Allow the tool to come up to full speed  
before touching the work material.  
6. 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.  
7. To create a smoother surface, keep the  
tool moving over the work surface.  
3. Secure loose work pieces using a vise  
or clamps (Sold separately) to prevent  
movement while working.  
8. To stop the tool, press and release the  
Trigger.  
4. There must not be hazardous objects,  
such as utility lines or foreign objects,  
nearby that will present a hazard while  
working.  
9. Allow the tool to come to a complete stop  
before setting it down.  
10. To prevent accidents, unplug the tool  
after use. Clean, then store the tool  
indoors out of children’s reach.  
5. You must use personal safety equipment  
including, but not limited to, ANSI-  
approved eye and hearing protection, as  
well as heavy work gloves.  
note: Do not cover the vents when the tool is  
in use. This may cause damage to the  
motor and reduce the efficiency of the  
tool.  
6. Before beginning work, provide for  
sparks and debris that will fly off the work  
surface.  
SKU 67648  
For technical questions, please call 1-800-444-3353.  
Page 15  
 
may damage the housing. To prevent  
electrical shock, do not allow water or  
other liquids to enter the motor vent  
holes.  
MAintenAnce And  
SerVicing  
Procedures not specifically  
explained in this manual must  
be performed only by a qualified  
technician.  
4. The grease in the gearbox will require  
replacement after extensive use of the  
grinder. Have the tool serviced by a  
qualified technician for this procedure.  
tO preVent  
SeriOuS injurY  
FrOM AccidentAl  
5.  
wArning! if the supply cord of  
this power tool is damaged, it must be  
replaced only by a qualified service  
technician.  
OperAtiOn:  
turn the power Switch of the tool  
off and unplug the tool from its  
electrical outlet before  
performing any inspection,  
maintenance, or cleaning  
procedures.  
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.  
cleaning, Maintenance, and  
lubrication  
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 wiring, and any  
other condition that may affect its safe  
operation.  
2. Periodically blow dust and grit out of  
the motor vents using dry compressed  
air. Always wear ANSI-approved safety  
goggles and NIOSH-approved breathing  
protection when performing this  
maintenance operation.  
3. AFter uSe, wipe external surfaces  
of the tool with a clean cloth. Do not  
use solvents or harsh cleaners as they  
Page 16  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
7. Replace the Brush Caps. Do not  
overtighten.  
carbon brush (40) replacement  
The Carbon Brushes (40) may  
require maintenance when the motor  
performance of the tool decreases or  
stops working completely. To maintain  
the brushes:  
Accessory Storage and handling  
1. Handle accessories carefully to prevent  
dropping or bumping. Do not use wheels  
that have been dropped or bumped.  
Side of Housing (36)  
2. Store accessories in shelves, racks,  
boxes, or drawers. Storage area must  
be kept dry, and above freezing. Any  
grinding wheels exposed to humidity or  
freezing temperatures must not be used.  
Brush Holder (39)  
Carbon Brush (40)  
Carbon Brush Cap (41)  
Figure 5  
1. Unscrew the Brush Holder Cap (41)  
using a flat head screwdriver (Sold  
separately).  
2. Pull the Brush from the Housing (36),  
noting the orientation of the old carbon  
brushes to prevent needless wear if they  
will be reinstalled.  
3. The Carbon Brushes (41) are  
approximately 1/2” long. If either carbon  
brush is worn down by more than 1/3,  
replace both carbon brushes.  
4. To clean old carbon brushes before  
reusing them, rub the contact areas with  
a pencil eraser.  
5. Hold the spring clips to the side and  
carefully, without forcing them, reinsert  
the old carbon brushes in the same  
orientation to reduce wear.  
6. When installing the carbon brushes,  
make sure the carbon portions of the  
carbon brushes contact the motor  
armature and that the springs operate  
freely.  
SKU 67648  
For technical questions, please call 1-800-444-3353.  
Page 17  
 
troubleshooting  
problem  
Tool will not start.  
possible causes  
1. Cord not connected.  
likely Solutions  
1. Check that cord is plugged in.  
2. No power at outlet.  
2. 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.  
3. Internal damage or wear. (Carbon  
brushes or switch, for example.)  
3. Have technician service tool.  
Tool operates slowly. 1. Excess pressure applied to workpiece. 1. Decrease pressure, allow tool to do the  
work.  
2. Power being reduced by long or small 2. Eliminate use of extension cord. If an  
diameter extension cord.  
extension cord is needed, use one with  
the proper diameter for its length and load.  
See Extension Cords in GROUNDING  
section.  
Performance  
Carbon brushes worn or damaged.  
Have qualified technician replace brushes.  
decreases over time.  
Excessive noise or Internal damage or wear. (Carbon  
Have qualified technician service tool.  
rattling.  
Overheating.  
brushes or bearings, for example.)  
1. Forcing tool to work too fast.  
1. Allow tool to work at its own rate.  
2. Blocked motor housing vents.  
2. Wear ANSI-approved safety goggles and  
NIOSH-approved dust mask/respirator  
while blowing dust out of motor using  
compressed air.  
3. Motor being strained by long or small  
diameter extension cord.  
3. Eliminate use of extension cord. If an  
extension cord is needed, use one with  
the proper diameter for its length and load.  
See Extension Cords in GROUNDING  
section.  
Tool does not grind, 1. Disc accessory may be loose on  
1. Check tightness of Outer Flange Arbor Nut  
or threaded disc accessory on Spindle. Be  
sure disc accessory is of correct dimension  
and Outer Flange Arbor Nut is tight.  
sand or wire brush  
effectively.  
Spindle.  
2. Disc accessory may be damaged, worn 2. Check condition and type of disc  
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.  
Page 18  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
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.  
pArtS liSt  
part  
description  
Qty  
1
1
1
1
1
1
1
4
4
1
1
1
6
6
1
1
1
1
1
4
1
1
1
2
1
1
part  
description  
Qty  
1
1
1
1
1
2
1
1
2
2
2
2
1
1
1
1
1
1
6
1
1
1
1
3
1
1
2
3
4
5
6
7
8
9
Outer Flange  
27 Bearing Cover  
Inner Flange  
28 Armature  
Wheel Guard Ø 180  
Socket Head Bolt M8 x 1.25 x 25mm  
Wheel Guard Nut M8  
Spindle  
Key M4 x 5 x 13  
Pan Head Screw M5 x 16  
Spring Lock Washer Ø 5  
29 Ball Bearing 608.2Z  
30 Bearing Bushing  
31 Baffle  
32 Tapping Screw ST4 X 75C  
33 Stator  
36 Housing  
38 Ring Terminal  
39 Brush Holder  
40 Carbon Brush  
41 Brush Holder Cap  
42 Plastic Plate  
43 Handle  
44 Cord Clamp  
46 Switch  
47 Trigger  
48 Handle Cover  
49 Tapping Screw ST4 x 16C  
50 Tapping Screw ST4 x 14F  
51 Cord Sleeve  
52 Cord  
53 Spanner  
54 Rubber Cap  
55 Hex Wrench  
10 Gear Box Cover  
11 Ball Bearing 6002.RS  
12 Bearing Cover  
13 Spring Lock Washer Ø 4  
14 Pan Head Screw M 4 x 10  
15 Gear  
16 Circlip Ø 14  
17 Friction Bearing  
18 E-Clip Ø 6  
19 Gear Box  
20 Tapping Screw ST5 x 45C  
21 Spindle Lock Button  
22 Spindle Lock Spring  
23 Auxiliary Handle  
24 Heck Nut M8  
25 Pinion  
26 Ball Bearing 6201.2RS  
SKU 67648  
For technical questions, please call 1-800-444-3353.  
Page 19  
 
ASSeMblY diAgrAM  
record product’s 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 available  
individually as replacement parts.  
Page 20  
For technical questions, please call 1-800-444-3353.  
SKU 67648  
 
liMited 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  
SKU 67648  
For technical questions, please call 1-800-444-3353.  
Page 21  
 

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