FLEXIBLE SHAFT
GRINDER/CARVER
Model 40432
SET up AND OpERATING INSTRuCTIONS
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
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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
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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
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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
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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.)
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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
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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
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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
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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
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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
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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
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