metabo G 400 Straight Grinder Instruction Manual

metabo G 400 Straight Grinder Instruction Manual

G 400
GP 400

Original instructions

www.metabo.com

1. Declaration of Conformity

Under our sole responsibility, we hereby declare that these straight grinders, identified by type and serial number 1), comply with all relevant requirements of the directives 2) and standards 3). Technical documents for 4) – see Page 3.

2. Specified Use

The straight grinders are designed…

• … for fine grinding work with mounted points on metal.
• … for fine cutting work with small cutting wheels on metal.
• … for routing with end mill cutters on non-ferrous metals, plastics, hardwood, etc.
• …for working with paint and round wire brushes
• …for working with polishing bobs
• …for working with felt polishing tools
• …for working with lamellar grinding wheels

The machine is not suitable for work with polishing bells. It is for dry processing only.

The user bears sole responsibility for any damage caused by improper use.

Generally accepted accident prevention regulations and the enclosed safety information must be observed.

3. General safety instructions

For your own protection and for the protection of your power tool, pay attention to all parts of the text that are marked with this symbol!

WARNING ­
Reading the operating instructions will reduce the risk of injury.

WARNING – Read all safety warnings and instructions. Failure to follow all safety warnings and instructions may result in electric shock, fire and/or serious injury.
Keep all safety instructions and information for future reference. Pass on your electrical tool only together with these documents.

4. Special Safety Instructions

4.1 Safety warnings common for grinding, sanding, wire brushing, polishing, carving or abrasive cutting-off operations:

a) This power tool is intended to function as a grinder and sander, wire brush, polisher, carving 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) 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.

c) The rated speed of the grinding accessories must be at least equal to the maximum speed marked on the power tool. Grinding accessories running faster than their rated speed can break and fly apart.

d) 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 controlled.

e) The arbour size of wheels, sanding drums or any other accessory must properly fit the spindle or collet of the power tool. 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.

f) Mandrel Mounted Wheels, sanding drums, cutters or other accessories must be fully inserted into the collet or chuck. If the mandrel is insufficiently held and/or the overhang of the wheel is too long, the Mounted Wheel may become loose and be ejected at high velocity.

g) Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks, sanding drum 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 workshop apron capable of stopping small abrasive or workpiece 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 workpiece or of a broken accessory may fly away and cause injury beyond immediate area of operation.

j) Hold 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) Always hold the tool firmly in your hands during the start-up. The reaction torque of the motor, as it accelerates to full speed, can cause the tool to twist.

l) Use clamps to support workpiece whenever practical. Never hold a small workpiece in one hand and the tool in the other hand while in use. Clamping a small workpiece allows you to use your hands to control the tool. Round material such as dowel rods, pipes or tubing have a tendency to roll while being cut, and may cause the bit to bind or jump toward you.

m) 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.

n) 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.

o) After changing the bits or making any adjustments, make sure the collet nut, chuck or any other adjusting devices are securely tightened. Loose adjustment devices can unexpectedly shift, causing loss of control, loose rotating components will be violently thrown.

p) 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.

q) Regularly clean the power tool’s air vents. The motor’s fan will draw dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

r) Do not operate the power tool near flammable materials. Sparks could ignite these materials.

s) Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

4.2 Kickback and Related Warnings

Kickback is a sudden reaction to a pinched or snagged rotating wheel, sanding band, 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.

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 power tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as 12 given below.

a) Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. The operator can control kickback forces, if proper precautions are taken.

b) 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.

c) Do not attach a toothed saw blade. Such blades create frequent kickback and loss of control.

d) Always feed the bit into the material in the same direction as the cutting edge is exiting from the material (which is the same direction as the chips are thrown). Feeding the tool in the wrong direction causes the cutting edge of the bit to climb out of the work and pull the tool in the direction of this feed.

e) When using rotary files, cut-off wheels, highspeed cutters or tungsten carbide cutters, always have the work securely clamped. These wheels will grab if they become slightly canted in the groove, and can kickback. When a cut-off wheel grabs, the wheel itself usually breaks. When a rotary file, high-speed cutter or tungsten carbide cutter grabs, it may jump from the groove and you could lose control of the tool.

4.3 Safety warnings specific for grinding and abrasive cutting-off operations:

a) Use only wheel types that are recommended for your power tool and only for recommended applications. For example: do not grind with the side of a cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.

b) For threaded abrasive cones and plugs use only undamaged wheel mandrels with an unrelieved shoulder flange that are of correct size and length. Proper mandrels will reduce the possibility of breakage.

c) Do not “jam” a cut-off wheel or apply excessive pressure. Do not attempt to make an excessive depth of cut. Overstressing the wheel increases the loading and susceptibility to twisting or snagging of the wheel in the cut and the possibility of kickback or wheel breakage.

d) Do not position your hand in line with and behind the rotating wheel. When the wheel, at the point of operation, is moving away from your hand, the possible kickback may propel the spinning wheel and the power tool directly at you.

e) When wheel is pinched, snagged or when interrupting a cut for any reason, switch off the power tool and hold the power tool motionless until the wheel comes to a complete stop. Never attempt to remove the cut-off wheel from the cut while the wheel is in motion otherwise kickback may occur. Investigate and take corrective action to eliminate the cause of wheel pinching or snagging.

f) Do not restart the cutting operation in the workpiece. Let the wheel reach full speed and carefully re-enter the cut. The wheel may bind, walk up or kickback if the power tool is restarted in the workpiece.

g) 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.

h) 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.

4.4 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) Allow brushes to run at operating speed for at least one minute before using them. During this time no one is to stand in front or in line with the brush. Loose bristles or wires will be discharged during the run-in time.

c) Direct the discharge of the spinning wire brush away from you. Small particles and tiny wire fragments may be discharged at high velocity during the use of these brushes and may become imbedded in your skin.

4.5 Additional Safety Instructions

WARNING ­
Always wear protective goggles.

Use elastic cushioning layers if they have been supplied with the abrasive and if required.

Observe the specifications of the tool or accessory manufacturer! Protect the discs from grease or impacts!

Abrasives must be stored and handled with care in accordance with the manufacturer’s instructions.

Never use parting grinder discs for roughing work. Do not apply pressure to the side of parting grinder discs.

The workpiece must lay flat and be secured against slipping, e.g. using clamps. Large workpieces must be supported adequately.

Keep hands away from the rotating tool! Remove swarf and similar material only when the machine is at a standstill.

Prior to use, ensure that the coated abrasive is properly fitted and secured. Run the tool in idling for 60 seconds in a safe position and bring to a standstill immediately if there are significant vibrations or if other deficiencies are determined. If such a situation occurs, check the machine to determine the cause.

Ensure that sparks produced during work do not constitute a risk to the user or other personnel and are not able to ignite inflammable substances.

Endangered areas must be protected with flame resistant covers. Make sure that fire-risk areas are always provided with suitable fire extinguishers.

When working in dusty conditions, ensure that ventilation openings are not blocked. If it becomes necessary to remove dust, first disconnect the power tool from the mains supply (use non-metallic objects) and avoid damaging internal components.

Damaged, eccentric or vibrating tools must not be used.

For safety reasons, always ensure the rubber sleeve is fitted while you work (4).

Pull the plug out of the plug socket before any adjustments, conversions or servicing are performed.

During machining, of metals in particular, conductive dust can form deposits inside the machine. This can lead to the transfer of electrical energy onto the machine housing. This can mean a temporary danger of electric shocks. This is why it is necessary when the machine is running to blow compressed air through the rear ventilation slots of the machine regularly, frequently and thoroughly. The machine must be held firmly in this case.

We recommend using a stationary extractor system and connecting a residual current circuit-breaker (FI) upstream. When the machine is shut down via the FI circuit-breaker, it must be checked and cleaned. For information on cleaning the motor, see chapter 8. Cleaning.

Reduce dust exposure:

Some dust created by using this power tool may contain chemicals known to cause cancer, allergic reaction, respiratory disease, birth defects or other reproductive harm. Some examples of these chemicals are: Lead from leadbased paints, crystalline silica from bricks and cement and other masonry products, Arsenic and chromium from chemically-treated lumber, hard wood like oak or beech, Metals, Asbestos. The risk from these exposures depends on how long you or bystanders are being exposed. Do not let particles enter the body.

To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles.

Observe the relevant guidelines for your material, staff, application and place of application (e.g. occupational health and safety regulations, disposal).

Collect the generated particles at the source, avoid deposits in the surrounding area.

Use suitable accessories for special work (see chapter 10.), thus less particles enter the environment in an uncontrolled manner.

Use a suitable extraction unit.

Reduce dust exposure with the following measures:

– Do not direct the escaping particles and the exhaust air stream at yourself or nearby persons or on dust deposits.

– Use an extraction unit and/or air purifiers. – Ensure good ventilation of the workplace and keep clean using a vacuum cleaner. Sweeping or blowing stirs up dust.

Vacuum or wash the protective clothing. Do not blow, beat or brush.

5. Overview

See page 2.

1 Collet chuck
2 Collet chuck nut
3 Spindle
4 Rubber sleeve
5 Slide switch
6 Main handle
7 Switch-on lock
8 Trigger *

*equipment-specific

6. Initial Operation

Before plugging in the device, check that the rated mains voltage and mains frequency, as specified on the rating label, match your power supply.

Australia: Always use a residual current device (RCD) protected supply with a rated residual current of 30 mA or less.

7. Use

7.1 Collet chucks

The tool’s shank diameter must correspond exactly to the collet bore of the collet chuck (1)!

Various collet chucks are available for different shank diameters. See Accessories section.

7.2 Fitting the tools

Pull the mains plug from the socket.

Only use tools that are suited to the no-load speed of your machine. See Technical Specifications.

The tool’s shank diameter must correspond exactly to the collet bore of the collet chuck (1)!

In the case of mounted points or mandrels, the maximum wheel overhang: l0 or maximum permissible length specified by the manufacturer must not be exceeded!

The maximum permitted shaft length is the sum of l0 and the maximum insertion depth Lmax (see chapter12.)

Insert the tool (with the full length of the shank) in the collet chuck (1).

Bring the spindle (3) to a standstill with the 13-mm spanner provided for this purpose.

Using the 19-mm spanner, tighten the collet chuck nut (2)

If there is no tool inserted in the collet chuck, you can tighten the collet chuck manually rather than with the spanner.

7.3 Removing the tools

Bring the spindle (3) to a standstill with the 13-mm spanner provided for this purpose.
Using the 19-mm spanner, unscrew the collet chuck nut (2).
Remove the tool.

7.4 Switching On and Off

Always guide the machine with both hands.

Switch on first, then guide the accessory towards the workpiece.

Avoid inadvertent starts: always switch the tool off when the plug is removed from the mains socket or if there has been a power cut.

In continuous operation, the machine continues running if it is forced out of your hands. Therefore always hold the machine with both hands using the handles provided (4), (6), maintain a steady position and concentrate on your work.

Machines with slide switch:

Switching on : Push the slide switch (5) forward. For continuous activation, now tilt downwards until it engages.

Switching off : Press the rear end of the slide switch (5) and release.

Machines with safety switch (with dead-man function):
(Machines with the designation WP…)

Switching on : Slide the switch-on lock (7) in the direction of the arrow and press the trigger (8).

Switching off : release the trigger switch (8).

7.5 Working instructions

Grinding, sanding, polishing or using wire brushes : Press down the machine evenly and move it from side to side over the surface.

Routing : Press down the machine evenly.

Separating:

Always work against the run of the disc (see illustration). Otherwise there is the danger of the machine kicking back from the cut out of control. Guide the machine evenly at a speed suitable for the material being processed. Do not tilt, apply excessive force or sway from side to side.

8. Cleaning

8.1 Motor cleaning

To clean the motor, apply jets of compressed air through the rear ventilation slots of the machine regularly, frequently and thoroughly. The machine must be held firmly in this case.

9. Accessories

Use only genuine Metabo accessories.

Use only accessories that fulfil the requirements and specifications listed in these operating instructions.

Fit accessories securely. Secure the machine if it is operated in a bracket. Loss of control can cause personal injury.

A Collets (including nut)
dia. 3 mm = 6.31947
dia. 1/8″ = 6.31948
dia. 6 mm = 6.31945
dia. 1/4″ = 6.31949
dia. 8 mm = 6.31946

B Clamping frame 6.28329 for clamping during work with flexible shafts, including:

C Clamping bracket 6.27107 for safe securing to the work bench (tighten clamping screw).

D Mounted points for fine grinding work on metal.

E Cutting wheel for fine cutting and grinding work on metal.

For a complete range of accessories, see www.metabo.com or the catalogue.

10. Repairs

Repairs to electrical tools must be carried out by qualified electricians ONLY!

If you have Metabo electrical tools that require repairs, please contact your Metabo service centre. For addresses see www.metabo.com.

You can download spare parts lists from www.metabo.com.

11. Environmental Protection

Observe national regulations on environmentally compatible disposal and on the recycling of disused machines, packaging and accessories.

Only for EU countries: Never dispose of power tools in your household waste! In accordance with European Guideline 2012/19/EU on used electronic and electric equipment and its implementation in national legal systems, used power tools must be collected separately and returned for environmentally compatible recycling.

12. Technical specifications

Explanation of details on page 3. Subject to changes serving technical progress.

The technical specifications quoted are subject to tolerances (in compliance with the relevant valid standards).

Emission values

Using these values, you can estimate the emissions from this power tool and compare these with the values emitted by other power tools. The actual values may be higher or lower, depending on the particular application and the condition of the tool or power tool. In estimating the values, you should also include work breaks and periods of low use. Based on the estimated emission values, specify protective measures for the user – for example, any organizational steps that must be put in place.

Wear ear protectors!

Metabowerke GmbH
Metabo-Allee 1
72622 Nuertingen
Germany
www.metabo.com

References

• Metabo - Power Tools for professional users

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