Choosing and Using Wheels and Abrasive Accessories Safely

Surface preparation tools can use many types of wheels and abrasive accessories. Accessories that look similar may be designed for different operations, mounting systems, speeds, materials, or guards.

Do not select an accessory based only on its diameter or whether it physically fits the tool. Before use, confirm that the tool, accessory type, dimensions, mounting system, speed rating, guard, and intended operation are compatible.

Using an incorrect or incompatible accessory can cause the accessory to break, separate from the tool, become jammed in the workpiece, or expose the operator to kickback and high-velocity debris.

Safety Notice: Read and understand all safety, product, and accessory instructions before installing, operating, maintaining, or changing accessories on a surface preparation tool. Only qualified and trained operators should install, adjust, or use the tool. This article provides general guidance and does not replace the manuals supplied with the tool or accessory.

Understand How IR Identifies Accessories

Ingersoll Rand product specifications may identify an accessory by its:

• Wheel or accessory type
• Intended operation
• Diameter
• Thickness
• Arbor, spindle, thread, collet, or shank size
• Maximum operating speed
• Required guard
• Tool configuration

All applicable specifications must match. A shared type number, diameter, or mounting size does not establish compatibility by itself.

For example:

• The G5351 IQV20™ Cordless Angle Grinder supports approved Type 27 grinding wheels and Type 1 cutting wheels in the sizes specified for the tool.
• The 326 Air Cut-Off Tool is specified for an approved Type 41 cut-off wheel.
• The 426 Air Reversible Cut-Off Tool is specified for an approved Type 1 cut-off wheel.
• Some M2 Series Angle Grinders are configured for Type 27 grinding wheels, while another M2 configuration is designed for an approved wire brush.
• Most M2 Series Die Grinders are identified for burrs, while the M2X075RG4 is identified for a mounted sanding drum.

These examples demonstrate why the exact model specifications must be checked. They are not a complete compatibility list.

Common Wheel and Accessory Categories

Ingersoll Rand surface preparation tools may support one or more of the following categories. Use an accessory only when it is expressly permitted by the tool’s safety and product information.

Grinding Wheels

Grinding wheels are designed for approved material-removal, shaping, deburring, weld-removal, or surface-preparation operations.

Type 27 wheels are commonly identified in IR angle-grinder specifications for grinding applications. Their shape and working surface differ from those of a thin cut-off wheel.

When using a grinding wheel:

• Use only the working surface permitted by the wheel manufacturer.
• Install the required grinding guard.
• Do not use a wheel that is too large or thick for the tool or guard.
• Do not exceed the wheel’s maximum operating speed.
• Avoid bumping the wheel against the workpiece or applying excessive pressure.
• Make smooth contact and remain alert for unusual vibration.

Do not assume every tool labeled as a grinder supports every grinding-wheel type.

Cut-Off Wheels

Cut-off wheels are designed to separate material using the edge of the wheel. Ingersoll Rand product specifications may identify approved cutting wheels as Type 1, Type 41, Type 42, or another type, depending on the tool and application.

A type number alone does not confirm compatibility. Check the permitted operation, diameter, thickness, mounting system, speed, and guard for the specific tool.

When using a cut-off wheel:

• Install the required cutting guard.
• Keep the wheel aligned with the cut.
• Support the workpiece so the cut remains open.
• Do not twist, bend, or force the wheel.
• Do not use the side of the wheel for grinding.
• Stop the tool if the wheel becomes pinched or jammed.
• Disconnect the power source before attempting to free the wheel.
• Inspect the wheel and mounting system before resuming work.

Never install a cut-off wheel on a grinder or die grinder unless the tool’s documentation specifically approves that wheel type, size, and application.

Mounted Grinding Wheels and Stones

Some die grinders support small grinding wheels or stones permanently mounted on a shaft. These accessories may be used for precision grinding, deburring, shaping, or work in confined areas when approved for the tool.

Before mounting:

• Match the accessory shaft to the tool’s collet size.
• Insert the shaft to the depth required by the product instructions.
• Keep the permitted overhang—the unsupported shaft length between the collet and accessory—as short as required.
• Confirm that the accessory’s maximum operating speed meets or exceeds the tool’s rated speed.
• Inspect the stone or wheel for cracks, chips, wear, or other damage.

Excessive overhang can increase vibration, bend the shaft, and contribute to accessory failure.

Carbide Burrs and Rotary Files

Carbide burrs and rotary files are not abrasive wheels, but IR product specifications may list them in the wheel or accessory field for die grinders. They remove material with cutting edges rather than an abrasive wheel surface.

Use only burrs or files with:

• The correct shank diameter
• An approved head size and shape
• A speed rating suitable for the tool
• The required insertion depth and permitted overhang
• An application approved by the accessory manufacturer

Do not substitute a burr for a grinding wheel—or a grinding wheel for a burr—without confirming that the tool supports the accessory.

Wire Wheels and Brushes

Approved wire wheels and brushes may be used to remove rust, scale, paint, residue, or other surface contamination. Because wires can loosen or break during operation, an incorrect brush size or speed can create a projectile hazard.

Before use:

• Confirm that the specific tool model supports a wire wheel or brush.
• Check the approved diameter, mounting system, and maximum speed.
• Install the guard required by the tool and accessory instructions.
• Inspect the brush for damage, looseness, severe wear, or missing wires.
• Keep people away from the path of possible wire fragments.
• Do not apply excessive pressure.

Not every angle grinder or die grinder is approved for wire-wheel use.

Sanding Discs

Sanding discs are intended for controlled surface abrasion. Depending on the disc and tool, they may be used for smoothing, blending, coating removal, or surface preparation.

Confirm the required:

• Disc type and diameter
• Backing pad
• Attachment method
• Maximum operating speed
• Guard or shroud
• Material and application

Do not install a sanding disc directly on a spindle unless the tool and disc are designed for that mounting arrangement. Never remove a required backing pad or substitute an improvised support.

Sanding Drums

A sanding drum uses an abrasive sleeve or band installed over an approved drum or mandrel. Some die-grinder models are specifically configured for mounted sanding drums.

Confirm that the:

• Tool is approved for a sanding drum
• Drum and sleeve dimensions match
• Mandrel or shank fits the collet
• Accessory is rated for the tool speed
• Abrasive sleeve is secure and undamaged

Do not install a sanding drum simply because its shank fits the collet. A tool operating at a higher speed than the drum permits can cause the accessory to fail.

Surface-Conditioning Accessories

Surface-conditioning discs or pads may be used for cleaning, blending, finishing, or preparing a surface when approved for the tool.

These accessories can differ significantly in construction and speed rating. Check the tool and accessory documentation rather than treating them as interchangeable with sanding discs, grinding wheels, or wire brushes.

A Wheel Type Number Is Not Enough

A wheel type identifies part of the accessory’s design, but it does not answer every compatibility question.

Before selecting a wheel, confirm all of the following:

If any factor cannot be confirmed, do not install or operate the accessory.

Check the Speed Rating

An accessory must be rated for at least the maximum speed of the tool.

Do not use an accessory whose maximum operating speed is lower than the tool’s rated speed. A wheel can fail even when the difference appears small.

For pneumatic grinders and sanders, the tool’s actual free speed must not exceed its rated speed. Complete the speed checks required by the applicable Product Safety Information, including checks after repair and at the specified service intervals.

Never attempt to make an accessory compatible by:

• Reducing air pressure without authorization
• Using an unapproved external speed-control device
• Modifying the tool
• Selecting a larger wheel intended to run at a lower speed

Use a tool and accessory designed to operate together.

Verify Dimensions and Mounting

Check the complete mounting system before installing an accessory.

Depending on the tool, this may include:

• Spindle or arbor thread
• Arbor-hole diameter
• Collet size
• Accessory shank diameter
• Backing flange
• Flange nut
• Mandrel
• Backing pad
• Wheel thickness
• Guard clearance

Use only the mounting hardware specified for the tool and accessory. Do not force an accessory onto a spindle or into a collet.

Do not enlarge an arbor hole, alter a shank, or use an improvised adapter. Do not use reducing bushings unless they are supplied or specifically recommended by the accessory manufacturer and permitted by the tool instructions.

After mounting, confirm that the accessory is centered, securely fastened, and able to rotate without contacting the guard or another part of the tool.

Inspect Accessories Before Use

Do not use an accessory that is:

• Cracked or chipped
• Bent, warped, or non-concentric
• Excessively worn
• Water-damaged or contaminated
• Missing pieces or wires
• Damaged around its arbor hole, shank, or mounting surface
• Improperly stored
• Beyond any date or service-life limit provided by its manufacturer
• Marked with an unreadable speed rating or identification
• Of unknown type or origin

Ingersoll Rand safety information warns against using bonded grinding accessories that have been exposed to freezing temperatures, extreme temperature changes, high humidity, solvents, water, or other liquids.

If the tool or accessory has been dropped or struck, disconnect the power source and inspect it before reuse. Discard the accessory if damage is found or its condition is uncertain.

Install or Change an Accessory Safely

Before installing, removing, or adjusting an accessory:

For pneumatic tools:

1. Turn off the air supply.
2. Bleed the remaining air pressure.
3. Disconnect the air hose.

For cordless tools:

1. Release the trigger or paddle switch.
2. Engage the trigger lock, if equipped.
3. Remove the battery as directed in the Product Information Manual.

Follow the model-specific mounting procedure. Use the correct flanges, nuts, washers, mandrels, pads, collets, and wrenches. Do not overtighten or undertighten the accessory.

Install and position the guard before reconnecting the power source.

Test the Tool After Installation

After installing an accessory:

• Confirm that all mounting components and guards are secure.
• Rotate the accessory by hand when directed and verify that it does not contact the guard.
• Keep yourself and others out of the plane or projected path of the accessory.
• Follow the run-in or test procedure specified for the tool and accessory.
• Stop immediately if the tool produces unusual vibration, noise, wobble, or movement.

Some Ingersoll Rand die-grinder instructions require a newly installed accessory to be run in a protected enclosure at gradually increasing speed for at least 60 seconds. Follow the procedure provided for the specific model; do not assume the same test applies to every surface preparation tool.

Stop Using the Tool If

Disconnect the power source and inspect the tool and accessory if:

• The accessory becomes loose, damaged, or jammed.
• The wheel contacts the guard.
• The tool develops unusual vibration, sound, or movement.
• The accessory does not run concentrically.
• The guard moves out of position.
• The tool or accessory is dropped or struck.
• The wheel is being used in a direction or manner not permitted by its manufacturer.
• The accessory identification or speed rating cannot be confirmed.
• The installed accessory does not match the tool specifications.

Do not resume work until the cause has been identified and corrected.

Manuals & Downloads

Use the model-specific Product Information and Product Safety Information to confirm accessory compatibility.

Examples of IR product specifications include:

• G5351 IQV20™ Cordless Angle Grinder
• 3445MAX and 345MAX Series Air Angle Grinders
• M2 Series Angle Air Grinders
• M2 Series Type 1 Air Grinder
• M2 Series Air Die Grinders
• 326 Air Cut-Off Tool
• 426 Air Reversible Cut-Off Tool
• Air Die Grinder Product Safety Information

If accessory compatibility cannot be confirmed, do not operate the tool. Contact an Ingersoll Rand distributor or Technical Support for assistance.

Need Help?

If assistance is needed in the product selection process, please contact Ingersoll Rand's Power Tool Technical Support Team through Submit a Request via our Help Center, email at IRTechSupport@irco.com, or call us at 866-TOOL-HLP (866-866-5457).