PORTER CABLE Cut Off Tool Grinder Instruction Manual

Instruction manual

CATALOG NUMBER

PCEG011

4-1/2 inch (115 mm) Cut Off Tool / Grinder

www.portercable.com

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SAFETY GUIDELINES – DEFINITIONS

It is important for you to read and understand this manual. The information it contains relates to protecting YOUR SAFETY and PREVENTING PROBLEMS. The symbols below are used to help you recognize this information.

DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTICE: Used without the safety alert symbol indicates potentially hazardous situation which, if not avoided, may result in property damage.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING: Read all safety warnings and all 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 or battery-operated (cordless) power tool.

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.
c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

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 earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock.
b) Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
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.
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.
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.

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.
b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, nonskid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
c) Prevent unintentional starting. Ensure the switch 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 the switch on invites accidents.
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.
e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.

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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.
g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards.

4) POWER TOOL USE AND CARE

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) Disconnect the plug from the power source and/or the battery pack from 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.
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.
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.
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.
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 different from those intended could result in a hazardous situation.

5) SERVICE

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 INSTRUCTIONS FOR ALL OPERATIONS

Safety Warnings Common for Grinding, Abrasive Cutting-Off Operations, Sanding, Wire Brushing, or Abrasive, Cutting-Off Operations
a) This power tool is intended to function as a grinder, sander, wire brush, or cut-off tool. 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.
b) Operations, such as polishing 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.
c) 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.
d) 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
e) 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.
f) Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbour hole of the accessory must fit the locating diameter of the flange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively and may cause loss of control.
g) Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheel 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.
h) Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and work shop 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 dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.
i) 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.
j) Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting accessory may contact hidden wiring or its own cord. Cutting accessory contacting a “live” wire may make exposed metal parts of the power tool “live” and could give the operator an electric shock.
k) 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.
l) 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.
m) 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.
n) 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.
o) Do not operate the power tool near flammable materials. Sparks could ignite these materials.
p) Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.
q) Do not use Type 11 (flaring cup) wheels on this tool. Using inappropriate accessories can result in injury.
r) Always use auxiliary handle. Tighten the handle securely. The auxiliary handle should always be used to maintain control of the tool at all times.
s) When starting the tool with a new or replacement wheel, or a new or replacement wire brush installed, hold the tool in a well protected area and let it run for one minute. If the wheel has an undetected crack or flaw, it should burst in less than one minute.
If the wire brush has loose wires, they will be detected. Never start the tool with a person in line with the wheel. This includes the operator.
t) To prevent the spindle end from contacting the bottom of the hole of the abrasive product, use accessories that have a threaded hole depth of at least 21mm. Failure to use an accessory with the appropriate thread depth could result in damage to the abrasive product and injury to the operator or persons in the area.
u) The arbor size of hubbed 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

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 tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:
a) 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 torque reaction or kickback forces, if proper precautions are taken.
b) Never place your hand near the rotating accessory. Accessory may kickback over your hand.
c) 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.
d) 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.
e) 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

a) Use only wheel types that are re- commended 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.
b) The grinding surface of the center depressed wheels must be mounted below the planned of the guard lip. An improperly mounted wheel that projects through the plane of the guard lip cannot be adequately protected.
c) 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 the operator from broken wheel fragments and accidental contact with wheel and sparks that could ignite clothing.
d) 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.
e) 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.
f) 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.

SAFETY WARNINGS FOR ABRASIVE CUTTING-OFF OPERATIONS

a) Do not “jam” the cut-off wheel or apply excessive pressure. Do not attempt to make excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or binding of the wheel in the cut and possibility of kickback or wheel breakage.
b) Do not position your body in line with and behind the rotating wheel. When the wheel, at the point of operation, is moving away from your body, the possible kickback may propel the spinning wheel and the power tool directly at you.
c) When wheel is binding or when interrupting a cut for any reason, switch off the power tool and hold the power tool motionless unitl the wheel comes to a complete stop. Never attempt to remove the cut-off wheel from the cut while wheel is in motion otherwise kickback may occur. Investigate and take corrective action to eliminate the cause of wheel binding.
d) Do not restart the cutting operation in the work piece. Let the wheel reach full speed and carefully reenter the cut. The wheel may bind, walk up or kickback if the power tool is restarted in the workpiece.
e) Support panels or any oversized workpiece to minimize the risk of wheel pinching and kickback. Large workpieces tend to sag under their own weight. Supports must be placed under the workpiece near the line of cut and near the edge of the workpiece on both sides of the wheel.
f) Use extra caution when making a “pocket cut” into existing walls or other blind areas. The protruding wheel may cut gas or water pipes, electrical wiring or objects that can cause kickback.

SAFETY WARNINGS SPECIFIC FOR SANDING OPERATIONS

a) Do not use excessively oversized sanding disc paper. Follow manufacturers 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.

SAFETY WARNINGS SPECIFIC FOR WIRE BRUSHING OPERATIONS

a) 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.
b) 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 and centrifugal forces.
c) Safety glasses: Safety Goggles or safety glasses with side shields and a full face shield compliant with ANSI Z87.1 eye protection (CAN/CPA Z94.3), must be worn by the operator and others that are within 50 feet of the use of this product/accessory.

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ADDITIONAL SAFETY INFORMATION

• Do not use Type 1/41 flat cut-off abrasive or diamond wheels without proper guard (see Accessories Chart in this manual.)

WARNING: Always wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.

WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:
• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.

WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the state of 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 and other masonry products, and
• arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

• Avoid prolonged contact with dust from power sanding, sawing, grinding, drilling, and other construction activities. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

WARNING: Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.

WARNING: The grinding wheel or accessory may loosen during coastdown of the tool when shut off. If grinding wheel or accessory loosens, it may dismount from the machine and may cause serious personal injury.

WARNING: Do not operate this tool for long periods of time. Vibration caused by the operating action of this tool may cause permanent injury to fingers, hands, and arms. Use gloves to provide extra cushion, take frequent rest periods, and limit daily time of use.

WARNING: When not in use, place grinder on a stable surface where it will not move inadvertently, roll or cause a tripping or falling hazard.

CAUTION: To reduce the risk of personal injury, use extra care when working into a corner or edge because a sudden, sharp movement of the tool may be experienced when the wheel or other accessory contacts a secondary surface or a surface edge.

• When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage. The smaller the gage number, the heavier the cord.

Minimum Gage for Cord Sets

Volts           Total Length of Cord in Feet
120V       0-25          26-50                 51-100         101-150

(0-7,6m)    (7,6-15,2m)    (15,2-30,4m)   (30,4-45,7m)

Ampere Rating
More Not more             American Wire Gage
Than   Than
0 –        6          18         16         16         14
6 –        10        18         16         14         12
10 –      12        16         16         14         12
12 –      16        14         12         Not Recommended

SAVE THESE INSTRUCTIONS

SYMBOLS
The label on your tool may include the following symbols. The symbols and their definitions are as follows:
V ………………..volts
A ………………..amperes
Hz ………………..hertz
W ………………..watts
min……………….minutes
∼ ………………..alternating current
or DC……..direct current
n ………………..rated speed
 ………………..Class I Construction (grounded)
………………..earthing terminal
………………..Safety alert symbol
…………………Class II Construction (double insulated)
…/min or rpm…revolutions or reciprocation per minute
SPM……………..Strokes per minute
5/8 -11 …………. Arbor size and Thread

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FUNCTIONAL DESCRIPTION
FIGURE A

1. Slider switch
2. Cord
3. Tool free guard
4. Body grip
5. Auxiliary handle (3 positions)
6. Spindle lock button
7. Wrench

count per inch
…………………Read instruction manual before use
…………………Use proper eye protection
…………………Use proper hearing protection
…………………Use proper respiratory protection

ASSEMBLY

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury.

ATTACHING THE AUXILIARY HANDLE

WARNING: This handle SHOULD BE USED AT ALL TIMES to maintain complete control of the tool. Always make sure the handle is securely attached. A three position auxiliary handle (5) is furnished with your grinder and can be screwed into either side of the grinder housing as well as into the top.

ACCESSORIES

It is important to choose the correct guards, backing pads and flanges to use with grinder accessories (see Accessories Chart in this manual.)

CAUTION: Accessories must be rated for at least the speed recommended on the tool warning label. Wheels and other accessories running over their rated accessory speed may fly apart and cause injury. Threaded accessories must have a 5/8 inch-11 hub. Every unthreaded accessory must have a 7/8 inch (22mm) arbor hole. If it does not, it may have been designed for a circular saw. Use only the accessories shown on pages 10 and 11 of this manual. Accessory ratings must always be above tool speed as shown on tool nameplate.

MOUNTING GUARD MOUNTING AND REMOVING GUARD

Turn off and unplug tool before making any adjustments or removing or installing attachments or accessories. Guards must be used with all grinding wheels, sanding flap discs, wire brushes, cut-off wheels and wire wheels. The tool may be used without a guard only when sanding with conventional sanding discs. Porter Cable model PCEG011 is provided with a guard intended for use with depressed center wheels (Type 27) and hubbed grinding wheels (Type 27). The same guard is designed for use with sanding flap discs (Type 27) and wire cup brushes. Grinding with wheels other than Type 27 require different accessory guards. A Type 1/41 guard is not provided.

NOTE: Porter Cable model PCEG011 is provided with a Type 27 guard only. A Type 1/41 guard for use with cut off wheels is available from a PORTER-CABLE Factory Service Center or a PORTER-CABLE Authorized Warranty Service Center. Please visit our Web Site www.portercable.com for the name of the nearest supplier.
Type 27 guards attach and are removed as described in Figures B and C.

FIGURE B

1. ATTACHING – Open the guard latch (8), and align the lugs on the guard (3) with the slots on the gear case cover.
2. Push the guard down until the guard lugs engage and rotate freely in the groove on the gear case hub.
3. With the guard latch open, rotate the guard (3) into the desired working position. The guard body should be positioned between the spindle and the operator to provide maximum operator protection.
4. Figure C – Close the guard latch to secure the guard on the gear case. You should not be able to rotate the guard by hand when the latch is closed. Do not operate the grinder with a loose guard or the clamp lever in open position.
5. REMOVING – To remove the guard, open the guard latch, rotate the guard so that the lugs on the guard are aligned with the slots on the gear case cover, and pull up on the guard.

FIGURE D

NOTE: The guard is pre-adjusted to the diameter of the gear case hub at the factory. If, after a period of time, the guard becomes loose, tighten the adjusting screw (10) with latch in the closed position and guard installed on the tool.

CAUTION: Do not tighten the adjusting screw with the latch in the open position. Undetectable damage to the guard or the mounting hub may result. If the guard cannot be tightened by the guard latch, do not use the tool and take the tool and guard to a service center to repair or replace the guard.

NOTE: Edge grinding and cutting can be performed with Type 27 wheels designed and specified for this purpose; 1/4” (6.35 mm) thick wheels are designed for surface grinding while thinner Type 27 wheels need to be examined for the manufacturer’s label to see if they can be used for surface grinding or only edge grinding/cutting. A Type 1/41 guard must be used for any wheel where surface grinding is forbidden. Cutting can also be performed by using a Type 1/41 wheel and a Type 1/41 guard.

OPERATING INSTRUCTIONS

WARNING: Always use proper eye protection that conforms to ANSI Z87.1 (CAN/ CSA Z94.3) while operating this power tool.

WARNING: Use clamps or another practical way to secure and support the work piece to a stable platform. Holding the work by hand or against your body leaves it unstable and may lead to loss of control.

NOTE: Before cutting any type of material, be sure it is firmly anchored or clamped to prevent slipping.

SLIDE SWITCH

CAUTION: Hold the auxiliary handle (5) and body of the tool (4) firmly to maintain control of the tool at start up and during use and until the wheel or accessory stops rotating. Make sure the wheel has come to a complete stop before laying the tool down.

CAUTION: Allow the tool to reach full speed before touching tool to the work surface. Lift the tool from the work surface before turning the tool off.

• To start the grinder, push the slider switch (1) forward using the edge of the slider toward the rear of the unit. Release the slider switch to turn the grinder off.
• For continuous operation, slide and depress the switch forward until it locates the lock ON position.
• To turn the tool off, press the rear of the slider switch. A spring action returns the switch to the OFF position.

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ACCESSORIES CHART

4-1/2 inch (115mm) Grinding Wheels

Type 27 guard                          Type 27 guard

                                 
Unthreaded backing flange         Type 27 hubbed wheel

Type 27 depressed center wheel     Threaded locking flange

4-1/2 inch (115mm) Type 1/41 Cutting Wheels

Type 1/41 guard                   Type 1/41 guard

Unthreaded backing flange       Unthreaded backing flange

                
abrasive cutting wheel            diamond cutting wheel

Threaded locking flange              Clamp nut

4-1/2 inch (115mm) Sanding Flap Discs

Type 27 guard                         Type 27 guard

Hubbed sanding flap disc      Unthreaded backing flange

non-hubbed sanding flap disc

Threaded locking flange

Wire Wheels

Type 27 guard              Type 27 guard Protector tipo 27

                   
3 inch wire cup brush           4 inch wire cup brush

Sanding Discs

Rubber backing pad
  Sanding disc
              Sanding clamp nut

*need to note that these are not incuded, etc.

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SPINDLE LOCK

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury. The spindle lock button (6) is provided to prevent the spindle from rotating when installing or removing wheels. Operate the spindle lock only when the tool is turned off, unplugged, and the wheel has come to a complete stop.

NOTE: Do not engage the spindle lock while the tool is operating. Damage to the tool will result and attached accessory may spin off possibly resulting in injury.
To engage the spindle lock, depress the spindle lock button shown in Figure E and rotate the spindle until you are unable to rotate the spindle further.

MOUNTING AND USING DEPRESSED GRINDING WHEELS AND SANDING FLAP DISCS

MOUNTING AND REMOVING HUBBED WHEELS

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury.

Hubbed wheels install directly on the 5/8 in.-11 threaded spindle.

1. Thread the wheel on the spindle by hand.
2. Depress the spindle lock button and use a wrench to tighten the hub of the wheel.
3. Reverse the above procedure to remove the wheel.
   Failure to properly seat the wheel before turning the tool on may result in damage to the tool or the wheel.

MOUNTING NON-HUBBED WHEELS

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury.

Depressed center Type 27 grinding wheels must be used with included flanges.

1. Figure F – Install the unthreaded backing flange (11) on spindle (12) with the raised section (pilot) against the wheel.
2. Place wheel against the backing flange, centering the wheel on the raised section (pilot) of the backing flange.
3. Figure G – While depressing the spindle lock button, thread the threaded locking flange (13) on spindle. Figure H – If the wheel you are installing is more than 1/8 inch (3mm) thick , place the threaded locking flange on the spindle so that the raised section (pilot) fits into the center of the wheel. Figure I – If the wheel you are installing is 1/8 inch (3mm) thick or less , place the threaded locking flange on the spindle so that the raised section (pilot) is not against the wheel.
4. While depressing the spindle lock button (6), tighten the threaded locking flange with included wrench.
5. To remove the wheel, depress the spindle lock button and loosen the threaded locking flange with included wrench.

NOTE: If the wheel spins after the threaded locking flange is tightened, check the orientation of the threaded clamp nut. If a thin wheel is installed with the pilot on the clamp nut against the wheel, it will spin because the height of the pilot prevents the clamp nut from holding the wheel.

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SURFACE GRINDING WITH GRINDING WHEELS

1. Allow the tool to reach full speed before touching the tool to the work surface.
2. Apply minimum pressure to the work surface, allowing the tool to operate at high speed. Grinding rate is greatest when the tool operates at high speed.
3. Figure J – Maintain a 20˚ to 30˚ angle between the tool and work surface.
4. Continuously move the tool in a forward and back motion to avoid creating gouges in the work surface.
5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

EDGE GRINDING WITH GRINDING WHEELS

Wheels used for cutting and edge grinding may break or kick back if they bend or twist while the tool is being used to do cut off work or deep grinding. Edge grinding/ cutting with a Type 27 wheel must be limited to shallow cutting and notching –less than 1/2” (13 mm) in depth when the wheel is new. Reduce the depth of cutting/notching equal to the reduction of the wheel radius as it wears down. Refer to the page 9 for more information. Edge grinding/cutting with a Type 1/41 wheel requires usage of a Type 1/41 guard.

1. Allow the tool to reach full speed before touching the tool to the work surface.
2. Apply minimum pressure to the work surface, allowing the tool to operate at high speed. Grinding rate is greatest when the tool operates at high speed.
3. Position yourself so that the open underside of the wheel is facing away from you.
4. Once a cut is begun and a notch is established in the workpiece, do not change the angle of the cut. Changing the angle will cause the wheel to bend and may cause wheel breakage. Edge grinding wheels are not designed to withstand side pressures caused by bending.
5. Remove the tool from the work surface before turning the tool off. Allow the tool to stop rotating before laying it down.

WARNING: Do not use edge grinding/cutting wheels for surface grinding applications if the wheel label has forbidden such use because these wheels are not designed for side pressures encountered with surface grinding. Wheel breakage and serious personal injury may result.

11

SURFACE FINISHING WITH SANDING FLAP DISCS

1. Allow the tool to reach full speed before touching the tool to the work surface.
2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Sanding rate is greatest when the tool operates at high speed.
3. Figure K – Maintain a 5˚ to 10˚ angle between the tool and work surface.
4. Continuously move the tool in a forward and back motion to avoid creating gouges in the work surface.
5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

MOUNTING SANDING BACKING PADS

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury.

NOTE: Guard may be removed when using sanding backing pads.

Proper guard must be reinstalled for grinding wheel, sanding flap disc, cutoff wheel, wire brush or wire wheel applications after sanding applications are complete.

1. Figure L – Place or appropriately thread backing pad (14) on the spindle.
2. Place the sanding disc (15) on the backing pad (14).
3. While depressing spindle lock, thread locking flange (16) onto the spindle, piloting the raised hub on the clamp nut into the center of sanding disc and backing pad.
4. Tighten the locking flange by hand. Then depress the spindle lock button while turning the sanding disc until the sanding disc and locking flange are snug.
5. To remove the wheel, grasp and turn the backing pad and sanding pad while depressing the spindle lock button.

USING SANDING BACKING PADS

Choose the proper grit sanding discs for your application. Sanding discs are available in various grits. Coarse grits yield faster material removal rates and a rougher finish. Finer grits yield slower material removal and a smoother finish.
Begin with coarse grit discs for fast, rough material removal. Move to a medium grit paper and finish with a fine grit disc for optimal finish.
Coarse                           16 – 30 grit
Medium                         36 – 80 grit
Fine Finishing              100 – 120 grit
Very Fine Finishing      150 – 180 grit

1. Allow the tool to reach full speed before touching tool to the work surface.
2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Sanding rate is greatest when the tool operates at high speed.
3. Figure M – Maintain a 5˚ to 15˚ angle between the tool and work surface. The sanding disc should contact approximately one inch (25mm) of work surface.
4. Move the tool constantly in a straight line to prevent burning and swirling of work surface. Allowing the tool to rest on the work surface without moving, or moving the tool in a circular motion causes burning and swirling marks on the work surface.
5. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before laying it down.

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PRECAUTIONS TO TAKE WHEN SANDING PAINT

1. Sanding of lead based paint is NOT RECOMMENDED due to the difficulty of controlling the contaminated dust. The greatest danger of lead poisoning is to children and pregnant women.
2. Since it is difficult to identify whether or not a paint contains lead without a chemical analysis, we recommend the following precautions when sanding any paint:

PERSONAL SAFETY

1. No children or pregnant women should enter the work area where the paint sanding is being done until all clean up is completed.

2. A dust mask or respirator should be worn by all persons entering the work area. The filter should be replaced daily or whenever the wearer has difficulty breathing.
   NOTE: Only those dust masks suitable for working with lead paint dust and fumes should be used. Ordinary painting masks do not offer this protection. See your local hardware dealer for the proper N.I.O.S.H. approved mask.

3. NO EATING, DRINKING or SMOKING should be done in the work area to prevent ingesting contaminated paint particles. Workers should wash and clean up BEFORE eating, drinking or smoking. Articles of food, drink, or smoking should not be left in the work area where dust would settle on them.

ENVIRONMENTAL SAFETY

1. Paint should be removed in such a manner as to minimize the amount of dust generated.
2. Areas where paint removal is occurring should be sealed with plastic sheeting of 4 mils thickness.
3. Sanding should be done in a manner to reduce tracking of paint dust outside the work area.

CLEANING AND DISPOSAL

1. All surfaces in the work area should be vacuumed and thoroughly cleaned daily for the duration of the sanding project. Vacuum filter bags should be changed frequently.
2. Plastic drop cloths should be gathered up and disposed of along with any dust chips or other removal debris. They should be placed in sealed refuse receptacles and disposed of through regular trash pick-up procedures. During clean up, children and pregnant women should be kept away from the immediate work area.
3. All toys, washable furniture and utensils used by children should be washed thoroughly before being used again.

MOUNTING AND USING WIRE BRUSHES AND WIRE WHEELS

Wire cup brushes or wire wheels screw directly on the grinder spindle without the use of flanges. Use only wire brushes or wheels provided with a 5/8 inch-11 threaded hub. A Type 27 guard is required when using wire brushes and wheels. Wear work gloves when handling wire brushes and wheels. They can become sharp. Wheel or brush must not touch guard when mounted or while in use. Undetectable damage could occur to the accessory, causing wires to fragment from accessory wheel or cup.

MOUNTING WIRE CUP BRUSHES AND WIRE WHEELS

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury.

1. Thread the wheel on the spindle by hand.
2. Depress spindle lock button and use a wrench on the hub of the wire wheel or brush to tighten the wheel.
3. To remove the wheel, reverse the above procedure.

Failure to properly seat the wheel hub before turning the tool on may result in damage to tool or wheel.

USING WIRE CUP BRUSHES AND WIRE WHEELS

Wire wheels and brushes can be used for removing rust, scale and paint, and for smoothing irregular surfaces.

NOTE: The same precautions should be taken when wire brushing paint as when sanding paint.

1. Allow the tool to reach full speed before touching the tool to the work surface.
2. Apply minimum pressure to work surface, allowing the tool to operate at high speed. Material removal rate is greatest when the tool operates at high speed.
3. F igure N – Maintain a 5˚ to 10˚ angle between the tool and work surface for wire cup brushes.
4. Maintain contact between the edge of the wheel and the work surface with wire wheels.
5. Continuously move the tool in a forward and back motion to avoid creating gouges in the work surface. Allowing the tool to rest on the work surface without moving, or moving the tool in a circular motion causes burning and swirling marks on the work surface.
6. Remove the tool from the work surface before turning the tool off. Allow the tool to stop rotating before setting it down.
   Use extra care when working over an edge, as a sudden sharp movement of grinder may be experienced.

MOUNTING AND USING CUTTING (TYPE 1/41) WHEELS

Cutting wheels include diamond wheels and abrasive discs. Abrasive cutting wheels for metal and concrete use are available. Diamond blades for concrete cutting can also be used.

NOTE: A closed, 2-sided Type 1/41 cutting wheel guard is sold separately and is required when using cutting wheels. Failure to use proper flange and guard can result in injury resulting from wheel breakage and wheel contact.

MOUNTING CLOSED (TYPE 1/41) GUARD

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury.

1. Figure O – Align the three lugs on the guard (3) with the three slots on the hub. This will align the lugs with slots on the gear case cover.
2. Push the guard down until the guard lug engages in the groove on the gear case hub.
3. Rotate guard (3) counterclockwise to lock it into place. The guard body should be positioned between the spindle and the operator to provide maximum operator protection.
4. Tighten the guard latch screw to secure the guard on the gear case cover. You should be unable to rotate the guard by hand. Do not operate grinder with a loose guard.
5. To remove the guard, loosen the guard latch screw. Then rotate the guard so that the three lugs on the guard (3) align with the three slots on the hub and pull up on the guard.

MOUNTING CUTTING WHEELS

WARNING: To prevent accidental operation, turn off and unplug tool before performing the following operations. Failure to do this could result in serious personal injury.

Matching diameter backing flange and threaded clamp nut (included with tool) must be used for cutting wheels.

1. Place the unthreaded backing flange on spindle with the raised section (pilot) facing up. The raised section (pilot) on the backing flange will be against the wheel when the wheel is installed.
2. Place the wheel on the backing flange, centering the wheel on the raised section (pilot).
3. Install the threaded clamp nut with the raised section (pilot) facing away from the wheel.
4. Depress the spindle lock button and tighten clamp nut with included wrench.
5. To remove the wheel, depress the spindle lock button and loosen the threaded clamp nut with included wrench.

USING CUTTING WHEELS

Do not use edge grinding/cutting wheels for surface grinding applications because these wheels are not designed for side pressures encountered with surface grinding. Wheel breakage and injury may result.

1. Allow tool to reach full speed before touching tool to work surface.
2. Apply minimum pressure to work surface, allowing tool to operate at high speed. Cutting rate is greatest when the tool operates at high speed.

14

TROUBLESHOOTING

outlet.
• Circuit fuse is blown.| • Replace circuit fuse. (If the product repeatedly causes the circuit fuse to blow, discontinue use immediately and have it serviced at a Porter Cable service center or authorized servicer.)
• Circuit breaker is tripped.| • Reset circuit breaker. (If the product repeatedly causes the circuit breaker to trip, discontinue use immediately and have it serviced at a Porter Cable service center or authorized servicer.)
• Cord or switch is damaged.| • Have cord or switch replaced at a Porter Cable Service Center or Authorized Servicer

For assistance with your product, visit our website at www.portercable.com for a list of service centers, or call the PorterCable Customer Care Center at 888-848-5175.

3. Once a cut is begun and a notch is established in the workpiece, do not change the angle of the cut. Changing the angle will cause the wheel to bend and may cause wheel breakage.
4. Remove the tool from work surface before turning tool off. Allow the tool to stop rotating before setting it down.

MAINTENANCE

CLEANING
Blowing dust and grit out of the motor housing using compressed air is a necessary maintenance procedure. Dust and grit from metal grinding often accumulate on interior surfaces and could create an electrical shock hazard if not cleaned out.

• Always handle accessories with care when mounting or removing.
• The best storage place for accessories is one that is cool and dry away from direct sunlight and excess heat or cold.

WARNING: ALWAYS use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty. ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:

• ANSI Z87.1 eye protection (CAN/CSA Z94.3),
• ANSI S12.6 (S3.19) hearing protection,
• NIOSH/OSHA/MSHA respiratory protection.
  Use only mild soap and a damp cloth to clean the tool. Never let any liquid get inside the tool; never immerse any part of the tool into a liquid.

LUBRICATION
Porter Cable tools are properly lubricated at the factory and are ready for use. Tools should be lubricated regularly every year depending on usage. (Tools used on heavy duty jobs and tools exposed to heat may require more frequent lubrication.) This lubrication should be attempted only by trained power tool repairperson’s such as those at Porter Cable service centers or in other qualified service personnel.

REPLACEMENT PARTS
Use only identical replacement parts. For a parts list or to order parts, visit our service website at www.portercableservicenet.com. You can also order parts from your nearest Porter Cable Factory Service Center or Porter Cable Authorized Warranty Service Center. Or, you can call our Customer Care Center at 888-848-5175.

SERVICE AND REPAIRS
All quality tools will eventually require servicing and/or replacement of parts. For information about PORTER-CABLE, its factory service centers or authorized warranty service centers, visit our website at www.portercable.com or call our Customer Care Center at 888-848-5175. All repairs made by our service centers are fully guaranteed against defective material and workmanship. We cannot guarantee repairs made or attempted by others. You can also write to us for information at PORTER-CABLE, 4825 Highway 45 North, Jackson, Tennessee 38305, (888) 848- 5175 – Attention: Product Service. Be sure to include all of the information shown on the nameplate of your tool (model number, type, serial number, etc.).

ACCESSORIES

  WARNING: Since accessories, other than those offered by PORTER-CABLE, have not been tested with this product, use of such accessories with this tool could be hazardous. To reduce the risk of injury, only PORTER-CABLE recommended accessories should be used with this product.
A complete line of accessories is available from your PORTER-CABLE Factory Service Center or a PORTER-CABLE Authorized Warranty Service Center. Please visit our Web Site www.portercable.com for a catalog or for the name of your nearest supplier.

THREE YEAR LIMITED WARRANTY
PORTER-CABLE will repair or replace, without charge, any defects due to faulty materials or workmanship for three years from the date of purchase for tools (two years for batteries). This warranty does not cover part failure due to normal wear or tool abuse. For further detail of warranty coverage and warranty repair information, visit www.portercable.com or call 888-848-5175. This warranty does not apply to accessories or damage caused where repairs have been made or attempted by others. This warranty gives you specific legal rights and you may have other rights which vary in certain states or provinces. In addition to the warranty, PORTER CABLE tools are covered by our:

1 YEAR FREE SERVICE: PORTER-CABLE will maintain the tool and replace worn parts caused by normal use, for free, any time during the first year after purchase.
90 DAY MONEY BACK GUARANTEE: If you are not completely satisfied with the performance of your PORTER-CABLE Power Tool for any reason, you can return it within 90 days from the date of purchase with a receipt for a full refund – no questions asked.
LATIN AMERICA: This warranty does not apply to products sold in Latin America. For products sold in Latin America, see country specific warranty information contained in the packaging, call the local company or see website for warranty information.
To register your tool for warranty service visit our website at www.portercable.com.
WARNING LABEL REPLACEMENT If your warning labels become illegible or are missing, call 888-848-5175 for a free replacement.

4825 Highway 45 North
Jackson, Tennessee 38305
888-848-5175
www.portercable.com

16

Catalog Number PCEG011                             N538888
September 2017                                                Printed in China

52

Documents / Resources

| PORTER CABLE Cut Off Tool Grinder [pdf] Instruction Manual
PCEG011, Cut Off Tool Grinder, 4-1 2 inch Cut Off Tool Grinder
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References

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