Chicago Electric Grinder 40432 User Manual

FLEXIBLE SHAFT  
GRINDER/CARVER  
Model 40432  
SET up AND OpERATING INSTRuCTIONS  
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 1999 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 Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing  
improvements, actual product may differ slightly from the product described herein. Tools required for  
assembly and service may not be included.  
For technical questions or replacement parts, please call 1-800-444-3353.  
REV 06g; Manual Revised 09k  
 
ranges and refrigerators. There is an  
increased risk of electric shock if your  
body is grounded.  
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.  
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  
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. Do not overreach. Keep proper  
footing and balance at all times. This  
enables better control of the power tool  
in unexpected situations.  
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.  
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  
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.  
Ground Fault Circuit Interrupter  
(GFCI) protected supply. Use of a  
GFCI reduces the risk of electric shock.  
3. personal safety  
h. Only use safety equipment that has  
been approved by an appropriate  
standards agency. Unapproved  
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.  
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.  
4. power tool use and care  
b. use personal protective equipment.  
Always wear eye protection. Safety  
equipment such as dust mask, non-  
skid safety shoes, hard hat, or hearing  
protection used for appropriate  
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.  
conditions will reduce personal injuries.  
c. prevent unintentional starting.  
Ensure the switch is in the off-  
b. Do not use the power tool if the  
switch does not turn it on and off.  
Any power tool that cannot be controlled  
position before connecting to power  
source and/or battery pack, picking  
SKU 40432  
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Page 3  
 
with the switch is dangerous and must  
be repaired.  
Flex Shaft Grinder Safety Warnings  
1. 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.  
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.  
2. Do not use a damaged accessory.  
Before each use inspect the  
accessory such as abrasive wheels  
for chips and cracks, backing pad  
for cracks, tear or excess wear, wire  
brush for loose or cracked wires. If  
power tool or accessory is dropped,  
inspect for damage or install an  
undamaged accessory.  
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.  
3. Do not bend the Flexible Shaft (21)  
at more than a 90° angle. Kinks or  
crimps in the Flexible Shaft will result in  
inefficient tool operation and create a  
safety hazard.  
4. Maintain labels and nameplates on  
the tool. These carry important safety  
information. If unreadable or missing,  
contact Harbor Freight Tools for a  
replacement.  
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.  
5. Avoid unintentional starting. Prepare to  
begin work before turning on the tool.  
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.  
6. 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.  
7. When using a handheld power tool,  
maintain a firm grip on the tool with both  
hands to resist starting torque.  
5. Service  
8. 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.  
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.  
REV 06g, 09e; 09k  
Page 4  
For technical questions, please call 1-800-444-3353.  
SKU 40432  
 
9. 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.)  
10. 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:  
13. 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.  
Vibration Safety  
• Any power cord must be properly  
grounded. Ground Fault Circuit  
Interrupter (GFCI) should also be  
implemented – it prevents sustained  
electrical shock.  
This tool vibrates during use. Repeated  
or long-term exposure to vibration may  
cause temporary or permanent physical  
injury, particularly to the hands, arms  
and shoulders. To reduce the risk of  
vibration-related injury:  
11. WARNING: Some dust created by power  
sanding, sawing, grinding, drilling, and  
other construction activities, contains  
chemicals known [to the State of  
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  
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  
should not use this tool. If you feel any  
symptoms related to vibration (such as  
tingling, numbness, and white or blue  
fingers), seek medical advice as soon as  
possible.  
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.)  
2. Do not smoke during use. Nicotine  
reduces the blood supply to the hands  
and fingers, increasing the risk of  
vibration-related injury.  
12. WARNING: Handling the cord on this  
product will expose you to lead, a  
3. Wear suitable gloves to reduce the  
vibration effects on the user.  
chemical known to the State of California  
to cause cancer, and birth defects or  
REV 09k  
SKU 40432  
For technical questions, please call 1-800-444-3353.  
Page 5  
 
4. Use tools with the lowest vibration when  
there is a choice.  
Double Insulated Tools: Tools with  
Two prong plugs  
5. Include vibration-free periods each day  
of work.  
6. Grip tool as lightly as possible (while still  
keeping safe control of it). Let the tool  
do the work.  
7. To reduce vibration, maintain the tool  
as explained in this manual. If any  
abnormal vibration occurs, stop use  
immediately.  
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  
SAVE THESE  
INSTRuCTIONS.  
GROuNDING  
Standard Association, and the National  
Electrical Code.  
TO pREVENT  
ELECTRIC SHOCK  
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.)  
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  
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  
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. 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.)  
electrician.  
3. The smaller the gauge number of the  
wire, the greater the capacity of the cord.  
For example, a 14 gauge cord can carry  
a higher current than a 16 gauge cord.  
(See Table A.)  
Page 6  
For technical questions, please call 1-800-444-3353.  
SKU 40432  
 
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.)  
Symbology  
Double Insulated  
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
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.  
No Load Revolutions per Minute  
(RPM)  
n xxxx/min.  
0
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  
LENGTH  
NAMEpLATE  
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 volt-  
age drop to five volts at 150% of  
the rated amperes.  
TABLE A  
SKU 40432  
For technical questions, please call 1-800-444-3353.  
Page 7  
 
Kinks or crimps in the shaft will result in  
inefficient tool performance.  
SpECIFICATIONS  
Electrical Input 120 V~ / 60 Hz / .5 A (No Load)  
3. Attach the Foot Control. Insert the Plug  
(29) into the Female Plug (28) which  
Motor Speed  
Flexible Shaft  
15,000 RPM (No Load)  
38”  
Chuck Capacity 5/32”  
comes off of the Foot Control (27). Insert  
the Power Plug (26) into the receptacle.  
uNpACKING  
4. Install a bit by using the Chuck Key (25)  
to loosen the Drill Chuck (24). Insert bit  
and then tighten the Drill Chuck by using  
the Chuck Key.  
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.  
Work piece and Work Area Set up  
1. Designate a work area that is clean and  
well-lit. The work area must not allow  
access by children or pets to prevent  
distraction and injury.  
OpERATING INSTRuCTIONS  
Read the ENTIRE IMpORTANT  
SAFETY INFORMATION  
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.  
section at the beginning of this  
manual including all text under  
subheadings therein before set up  
or use of this product.  
Tool Set up  
TO pREVENT  
SERIOuS INjuRY  
FROM ACCIDENTAL  
3. Secure loose work pieces using a vise  
or clamps (not included) to prevent  
movement while working.  
OpERATION:  
Turn the power Switch of the tool  
off and unplug the tool from its  
electrical outlet before adjusting  
tool or installing accessories.  
4. There must not be objects, such as utility  
lines, nearby that will present a hazard  
while working.  
1. Before operating, find a suitable spot  
in the work area to attach the Holder  
(1) and the Hanger (4). Drive two  
(2) screws (not included) through the  
Electric Rings and through the Holder.  
Attach the Hanger to the Motor Housing  
(7) with the two (2) Screws (6).  
2. Inspect the Flexible Shaft (21) and make  
certain that it is securely connected to  
the Motor Housing Unit (7). Do not use  
the Shaft at an angle greater than 90°.  
REV 06g, 08l, 09e  
Page 8  
For technical questions, please call 1-800-444-3353.  
SKU 40432  
 
General Operating Instructions  
TO pREVENT INjuRY  
FROM BuRNS:  
With normal use, the motor  
housing (7) will get hot. This is  
normal and not harmful to the  
tool. However, the hot surface of  
the housing may be harmful if  
touched or present a danger if it  
is within three (3) feet of  
flammable material. If the tool is  
used for a prolonged period of  
time and if the housing becomes  
EXTREMELY HOT, stop using the  
tool until the unit cools off. Also  
the Chuck housing will become  
warm. If it becomes  
uncomfortable to hold, rest the  
tool and allow it to cool down.  
1. Before using this tool, make sure that  
clothing, hair and work pieces are out of  
the way of the Hand Piece and the Bit.  
Turn the tool ON.  
2. Adjust tool speed by pressing on the  
Foot Control (27).  
3. If the Flexible Shaft (21) does not  
operate properly, inspect the connections  
to the Flexible Shaft.  
4. To prevent accidents, turn off the tool  
and disconnect its power supply after  
use. Clean, then store the tool indoors  
out of children’s reach.  
REV 04c, 04l, 08l, 09c, 09e  
SKU 40432  
For technical questions, please call 1-800-444-3353.  
Page 9  
 
2. Using a small screwdriver, remove  
the Carbon Brushes (8). When you  
remove the Carbon Brush screws, the  
Brush may spring out. Do not lose the  
Brush. If the brush does not spring out,  
gently remove it using the tip of your  
screwdriver. Examine the Brush surface.  
The surface should be smooth and  
clean. If scratch marks appear, or  
if the brush is broken, replace the  
brush immediately with an approved  
replacement brush from Harbor Freight  
tools.  
MAINTENANCE AND  
SERVICING  
Procedures not specifically  
explained in this manual must  
be performed only by a qualified  
technician.  
TO pREVENT  
SERIOuS INjuRY  
FROM ACCIDENTAL  
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.  
3. If the brush appears fine and only dirty,  
you may clean it off with a pencil eraser.  
Gently rub with the eraser until the dirt  
has been removed. Remove any eraser  
dust which may have occurred during  
cleaning.  
TO pREVENT SERIOuS INjuRY  
FROM TOOL FAILuRE:  
Do not use damaged equipment.  
If abnormal noise or vibration  
occurs, have the problem  
4. Re-insert the Brushes. There is a spring  
and plug attached to each brush.  
corrected before further use.  
1. BEFORE EACH uSE, inspect the  
general condition of the tool. Check for  
loose hardware, misalignment or binding  
of moving parts, cracked or broken parts,  
damaged electrical wiring, and any  
other condition that may affect its safe  
operation.  
2. AFTER uSE, wipe external surfaces of  
the tool with clean cloth.  
3.  
WARNING! If the supply cord of  
this power tool is damaged, it must be  
replaced only by a qualified service  
technician.  
Replacement of Carbon Brushes  
1. Replace the Carbon Brushes in pairs.  
Normal Carbon Brush life is from 500 to  
2000 hours, depending on use.  
REV 04c, 04l, 08l, 09c, 09e  
Page 10  
For technical questions, please call 1-800-444-3353.  
SKU 40432  
 
pARTS LIST AND ASSEMBLY DIAGRAM  
part  
Description  
Qty.  
1
1
1
2
1
2
1
1
4
5
6
7
8
9
Holder  
Hanger  
Rubber Ring  
Screw  
Motor Housing  
Carbon Brush  
Stator  
10 Screw  
2
11 Gasket  
12 Rubber Ring  
13 Bearing  
1
1
1
14 Cover  
1
15 Screw  
2
16 Rotator  
1
17 Impeller  
1
18 Bearing  
1
19 Cover  
1
20 Screw  
2
21 Flexible Shaft  
22 Chuck Housing  
23 Bearing Set*  
24 Chuck  
1
1
1
1
25 Chuck Key  
26 Power Plug  
27 Foot Control  
28 Plug-Female  
29 Plug  
1
1
1
1
1
*Includes 2 Bearings and Shaft  
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.  
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.  
REV 04c, 06b, 09e  
SKU 40432  
For technical questions, please call 1-800-444-3353.  
Page 11  
 
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.  
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  
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  
MERCHANTABILITy AND FITNESS.  
REV 08l  
Page 12  
For technical questions, please call 1-800-444-3353.  
SKU 40432  
 

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