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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 wire size. Guidelines for Using Extension Cords • If you are using an extension cord outdoors, be sure it is marked with the suffix “W-A” (“W” in Canada) to indicate that it is acceptable for outdoor use. • Be sure your extension cord is properly wired and in good electrical condition. Always replace a damaged extension cord or have it repaired by a qualified person before using it. • Protect your extension cords from sharp objects, excessive heat and damp or wet areas. Recommended Minimum Wire Gauge for Extension Cords* Nameplate Amperes Extension Cord Length 25' 50' 75' 100' 150' 200' 0 - 5 16 16 16 14 12 12 5.1 - 8 16 16 14 12 10 -8.1 - 12 14 14 12 10 -- 12.1 - 15 12 12 10 10 -- 15.1 - 20 10 10 10 -- - * Based on limiting the line voltage drop to five volts at 150% of the rated amperes. READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE. page 4 TOOL ASSEMBLY WARNING! To reduce the risk of injury, always unplug tool before attaching or removing accessories or making adjustments. Use only specifically recommended accessories. Others may be hazardous. Installing Collets MILWAUKEE Die Grinders feature a special collet and collet nut. The collet must be attached to the collet nut before installing the collet asembly to the tool. Be sure that the collet size matches the size of the mounted wheel mandrel you will use, otherwise the collet may break. 1. To assemble, place collet on an even surface, take nut and place over collet (Fig. 1). Fig. 1 2. Position nut squarely over collet (Fig. 2). Fig. 2 3. Snap nut and collet together by firmly applying downward pressure onto assembly with the palm of hand (Fig. 3). 4. To disassemble collet from nut, hold nut firmly with one hand and press the collet to one side with the other hand (Fig. 4). Fig. 4 Installing Grinding Points (Fig. 5) MILWAUKEE offers a complete line of grinding points for finish grinding, beveling, sharpening and de-burring (see "Accessories"). Fig. 5 Insert mandrel a minimum Overhang about 1/2" of 3/4" inside the collet Collet Mandrel Grinding point 1. Remove dust and debris from the collet body before inserting grinding points. 2. Insert the collet with the collet nut attached into the collet body. Thread the collet nut onto the spindle but do not tighten it yet. 3. Clean the grinding point mandrel, then insert it a minimum of 3/4" into the collet. The mandrel will overhang the collet and the grinding point about 1/2". 4. Hold the spindle shaft steady with a 1/2" open end wrench and securely tighten the collet nut with an 11/16" open end wrench. 5. Reverse the procedure when removing the grinding point. Fig. 3 WARNING! To reduce the risk of injury, always securely tighten the collet to the grinders and clean mandrels before inserting them into the collet. Otherwise the high-speed rotation of the tool could force the grinding point to fly out of the collet. page 5 OPERATION MAINTENANCE WARNING! To reduce the risk of injury, wear safety goggles or glasses with side shields. Unplug the tool before changing accessories or making adjustments. WARNING! To reduce the risk of injury, always unplug your tool before performing any maintenance. Never disassemble the tool or try to do any rewiring on the tool's electrical system. Contact a MILWAUKEE service facility for ALL repairs. WARNING! If the grinder begins vibrating, immediately stop the motor and check to see if the grinding point is dull. Dull grinding points will cause the tool to vibrate and could force the collet to fly off the tool. Always replace or sharpen dull grinding points. Grinding Always hold the grinder firmly before starting the motor. To start the motor for Cat. No. 5192, turn the toggle switch ON. To start Cat. No. 5194, press the paddle switch. For Cat. No. 5196, pull the trigger. Using the Trigger Lock Mechanism (Cat. No. 5196) The lock button holds the trigger in the ON position for continuous full speed use. 1. To lock the trigger, hold the lock button in while pulling the trigger, then release the trigger. 2. To unlock the trigger, pull the trigger and release. The lock button will pop out. Allow the motor to reach full speed and then place the grinding point on the work surface. The tool is designed to work most efficiently with only light pressure. Excessive pressure will burn the work surface, damage the grinding point, bend the mandrel, and cause slow grinding. When a grinding point becomes dull, the grinder may start to vibrate. When this happens immediately stop using the grinding point. Vibration could loosen the collet, causing the grinding point to fly off the tool. Replace a dull grinding point with a new one or use a dressing stone to sharpen the dull point. Handle grinding points carefully. Dropping them or dropping the grinder could cause the point to shatter. Do not operate the grinder carelessly because it may cause the grinding point to...

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