Operator's manual [PDF] (21 pages)
- Updated: 02.05.2026
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TO REDUCE THE RISK OF INJURY, USER MUST READ OPERATOR'S MANUAL.
AFIN DE RÉDUIRE LE RISQUE DE BLESSURES, L'UTILISATEUR DOIT LIRE LE
MANUEL DE L'UTILISATEUR.
PARA REDUCIR EL RIESGO DE LESIONES, EL USUARIO DEBE LEER EL MANUAL
DEL OPERADOR.
Cat. No.
No de cat.
6140
6141
6145
OPERATOR'S MANUAL
MANUEL de L'UTILISATEUR
MANUAL del OPERADOR
HEAVY-DUTY SANDERS/GRINDERS
EXTRA ROBUSTE PONCEUSE-RECTIFIEUSE
LIJADORAS/ESMERILADORAS HEAVY-DUTY
2
3
WORK AREA SAFETY
ELECTRICAL SAFETY
PERSONAL SAFETY
WARNING
READ ALL INSTRUCTIONS
Failure to follow all instructions listed below may result in electric shock, fi re and/or
serious injury. The term "power tool" in all of the warnings listed below refers to your
mains-operated (corded) power tool or battery-operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
GENERAL SAFETY RULES — FOR ALL POWER TOOLS
1.
Keep work area clean and well lit.
Cluttered or dark areas invite acci-
dents.
2.
Do not operate power tools in ex-
plosive atmospheres, such as in the
presence of fl ammable liquids, gases,
or dust. Power tools create sparks which
may ignite the dust or fumes.
3.
Keep children and bystanders away
while operating a power tool. Distrac-
tions can cause you to lose control.
4.
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.
Unmodifi ed plugs and matching outlets
will reduce risk of electric shock.
5.
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.
6.
Do not expose power tools to rain or
wet conditions. Water entering a power
tool will increase the risk of electric
shock.
7.
Do not abuse the cord. Never use the
cord for carrying, pulling, or unplug-
ging the power tool. Keep cord away
from heat, oil, sharp edges, or mov-
ing parts. Damaged or entangled cords
increase the risk of electric shock.
8.
When operating a power tool out-
doors, use an extension cord suitable
for outdoor use. Use of a cord suitable
for outdoor use reduces the risk of elec-
tric shock.
9.
Stay alert, watch what you are do-
ing and use common sense when
operating a power tool. Do not use
a power tool while you are tired or
under the infl uence of drugs, alcohol
or medication. A moment of inattention
while operating power tools may result
in serious personal injury.
10. Use safety equipment. Always wear
eye protection. Safety equipment such
as dust mask, non-skid safety shoes,
hard hat, or hearing protection used
for appropriate conditions will reduce
personal injuries.
11. Avoid accidental starting. Ensure the
switch is in the off-position before plug-
ging in. Carrying tools with your fi nger on
the switch or plugging in power tools that
have the switch on invites accidents.
12. Remove any adjusting key or wrench
before turning the power tool on. A
wrench or a key left attached to a rotat-
ing part of the power tool may result in
personal injury.
13. Do not overreach. Keep proper foot-
ing and balance at all times. This
enables better control of the power tool
in unexpected situations.
14. Dress properly. Do not wear loose
clothing or jewellery. Keep your hair,
clothing and gloves away from moving
parts. Loose clothes, jewellery, or long
hair can be caught in moving parts.
15. If devices are provided for the connec-
tion of dust extraction and collection
facilities, ensure these are connected
and properly used. Use of these de-
vices can reduce dust-related hazards.
POWER TOOL USE AND CARE
16. Do not force the power tool. Use the
correct power tool for your applica-
tion. The correct power tool will do the
job better and safer at the rate for which
it was designed.
17. 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.
18. 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 preven-
tive safety measures reduce the risk of
starting the tool accidentally.
19. Store idle power tools out of the reach
of children and do not allow persons
unfamiliar with the power tools or
these instructions to operate power
tools. Power tools are dangerous in the
hands of untrained users.
20. 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.
21. Keep cutting tools sharp and clean.
Properly maintained cutting tools with
sharp cutting edges are less likely to
bind and are easier to control.
22. Use the power tool, accessories and
tool bits etc., in accordance with
these instructions and in the manner
intended for the particular type of
power tool, 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.
SERVICE
23. Have your power tool serviced by a
qualifi ed repair person using only
identical replacement parts. This will
ensure that the safety of the power tool
is maintained.
SPECIFIC SAFETY RULES
1.
Always use proper guard with grind-
ing wheel. A guard protects operator
from broken wheel fragments.
2.
Accessories must be rated for at least
the speed recommended on the tool
warning label. Wheels and other acces-
sories running over rated speed can fl y
apart and cause injury.
3.
Make sure all wheel fl anges and other
mounting hardware are in good con-
dition and are always used properly.
Defective or missing parts may dam-
age the wheels and other accessories.
Always use mounting hardware supplied
with the tool.
4.
Hold tools by insulated gripping sur-
faces when performing an operation
where the cutting tool may contact
hidden wiring or its own cord. Con-
tact with a “live” wire will make exposed
metal parts of the tool “live” and shock
the operator.
5.
Keep hands away from all cutting
edges and moving parts.
6.
Maintain labels and nameplates.
These carry important information.
If unreadable or missing, contact a
MILWAUKEE service facility for a free
replacement.
7.
WARNING: Some dust created by
power sanding, sawing, grinding, drill-
ing, and other construction activities
contains chemicals known to cause
cancer, birth defects or other reproduc-
tive harm. Some examples of these
chemicals are:
•
lead from lead-based paint
•
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 ven-
tilated area, and work with approved
safety equipment, such as those dust
masks that are specially designed to
fi lter out microscopic particles.
4
5
FUNCTIONAL DESCRIPTION
Double Insulated
Symbology
Volts Alternating Current/
Direct Current
Amps
Underwriters Laboratories, Inc.,
United States and Canada
1.
Side handle
2.
Grinding wheel
3.
Lock lever
4.
Wheel guard
5.
Spindle lock button
6.
Side handle sockets
7.
Paddle trigger
(under body of tool)
RPM
10,000
10,000
10,000
Volts
AC/DC
120
120
120
Cat.
No.
6140
6141
6145
Specifi cations
Amps
5.5
5.5
5.5
Spindle
Size
5/8" - 11
5/8" - 11
1/2" - 13
Wheel
Size
4 -1/2"
5"
4 -1/2"
Min.
Wheel
RPM
Rating
12,000
12,000
12,000
1
6
2
4
5
3
No Load Revolutions
per Minute (RPM)
7
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 con-
nected to the tool's grounding system and
must never be attached to an electrically
“live” terminal.
Your tool must be plugged into an appropri-
ate outlet, properly installed and grounded in
accordance with all codes and ordinances.
The plug and outlet should look like those
in Figure A.
Double Insulated Tools:
Tools with Two Prong Plugs
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 Standard
Association and the National Electrical
Code. Double Insulated tools may be used
in either of the 120 volt outlets shown in
Figures B and C.
Grounded Tools:
Tools with Three Prong Plugs
Tools marked “Grounding Required” have a
three wire cord and three prong grounding
plug. The plug must be connected to a prop-
erly grounded outlet (See Figure A). 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.
Fig. B
Fig. C
Fig. A
Improperly connecting the grounding
wire can result in the risk of electric
shock. Check with a qualifi ed electri-
cian if you are in doubt as to whether
the outlet is properly grounded. Do
not modify the plug provided with
the tool. Never remove the grounding
prong from the plug. Do not use the
tool if the cord or plug is damaged.
If damaged, have it repaired by a
MILWAUKEE service facility before
use. If the plug will not fi t the outlet,
have a proper outlet installed by a
qualifi ed electrician.
GROUNDING
WARNING
6
7
WARNING
TOOL ASSEMBLY
To reduce the risk of injury,
always unplug tool before attaching
or removing accessories or making
adjustments. Use only specifi cally
recommended accessories. Others
may be hazardous.
WARNING
To reduce the risk of injury, wear
safety goggles or glasses with side
shields. Unplug the tool before
changing accessories or making
adjustments.
OPERATION
Installing Side Handle
The side handle may be installed on the top
of the gear case or on either side of gear
case for right or left handed use. Position
side handle in the location which offers
best control and guard protection. To install,
thread side handle into side handle socket
on desired side of gear case and tighten
securely.
Starting and Stopping the Motor
Plug in the tool. To start the tool, squeeze
the paddle trigger. Release the paddle trig-
ger to stop tool.
1.
To start the tool, squeeze the paddle
trigger.
2.
To stop the tool, release the paddle
trigger.
Sanding Disc/Grinding Wheel Selection
Use sanding discs and grinding wheels
that are:
•
correct size as written on tool's name-
plate.
•
correct wheel type and grit for the job.
•
rated at or above the RPM listed in
the "WARNING" section on the tool's
nameplate.
Use backing pads, adapters, and other ac-
cessories that are:
•
correct size for tool and for sanding disc
or grinding wheel.
•
rated at or above the RPM listed in
the "WARNING" section on the tool's
nameplate.
• the proper accessory for the job.
Aluminum Oxide: For fast cutting, general
purpose discs for most metal jobs. Best for
cold-rolled steel, stainless steel or metals
requiring tough, fast cutting, long lasting
abrasives.
Aluminum Zirconia Bi-Cut: Unique grit pat-
tern is arranged in clusters for faster stock re-
moval and cleaning. Ideal for removing paint
from cars, boats, etc. without clogging.
Ceramic: Lasts up to 3 times longer than
aluminum oxide discs. For general metal
working. Ideal for tough jobs.
Sanding Disc/Grinding Wheel Material
Sanding discs and grinding wheels are made
of various materials and are designed for
different jobs. Be sure that you choose the
proper sanding disc or grinding wheel for the
job you plan to do.
Selecting Sanding Discs & Grit
Refer to the table below to select the correct
type of sanding disc for your job. Generally,
use 24 or 36 grit for heavy stock removal;
50, 60, or 80 grit for medium stock removal
and 120 grit for fi nishing. Always begin with
a coarse grit, using successively fi ner grits
to obtain the desired fi nish. See Catalogor a
complete list of MILWAUKEE sanding discs.
WARNING
To reduce the risk of personal
injury and damage to the tool,
use ONLY accessories rated at
or above the RPM listed on the
“WARNING” section of the tool's
nameplate.
Grounded tools require a three wire exten-
sion cord. Double insulated tools can use
either a two or three wire extension cord.
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. Refer to the table
shown to determine the required minimum
wire size.
The smaller the gauge number of the wire,
the greater the capacity of the cord. For ex-
ample, a 14 gauge cord can carry a higher
current than a 16 gauge cord. When using
more than one extension cord to make up
the total length, be sure each cord contains
at least the minimum wire size required. 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 out-
doors, be sure it is marked with the suffi x
“W-A” (“W” in Canada) to indicate that it
is acceptable for outdoor use.
•
Be sure your extension cord is prop-
erly wired and in good electrical
condition. Always replace a damaged
extension cord or have it repaired by a
qualifi ed person before using it.
•
Protect your extension cords from sharp
objects, excessive heat and
damp or wet areas.
READ AND SAVE ALL INSTRUCTIONS FOR FUTURE USE.
Recommended Minimum Wire Gauge
for Extension Cords*
Extension Cord Length
* Based on limiting the line voltage drop to
fi ve volts at 150% of the rated amperes.
Nameplate
Amperes
0 - 2.0
2.1 - 3.4
3.5 - 5.0
5.1 - 7.0
7.1 - 12.0
12.1 - 16.0
16.1 - 20.0
25'
18
18
18
18
16
14
12
75'
18
18
16
14
12
10
100'
18
16
14
12
10
150'
16
14
12
12
50'
18
18
18
16
14
12
10
EXTENSION CORDS
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