metabo HPT G12SR4 Disc Grinder Instruction Manual

G12SR4
Disc Grinder

HPT G12SR4 Disc Grinder

SAFETY INSTRUCTIONS AND INSTRUCTION MANUAL

WARNING
IMPROPER OR UNSAFE use of this power tool can result in death or serious bodily injury!
This manual contains important information about product safety. Please read and understand this manual BEFORE operating the power tool. Please keep this manual available for other users and owners before they use the power tool. This manual should be stored in safe place.
DOUBLE INSULATION

IMPORTANT SAFETY INFORMATION
Read and understand all of the safety precautions, warnings and operating instructions in the Instruction Manual before operating or maintaining this power tool.
Most accidents that result from power tool operation and maintenance are caused by the failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing a potentially hazardous situation before it  occurs, and by observing appropriate safety procedures.
Basic safety precautions are outlined in the “SAFETY” section of this Instruction Manual and in the sections which contain the operation and maintenance instructions.
Hazards that must be avoided to prevent bodily injury or machine damage are identified by WARNINGS on the power tool and inthis Instruction Manual.
NEVER use this power tool ina manner that has not been specifically recommended by metabo HPT.

MEANINGS OF SIGNAL WORDS
WARNING indicates a potentially hazardous situations which, if ignored, could result in death or serious injury.
CAUTION indicates a potentially hazardous situations which, if not avoided, may result in minor or moderate injury, or may cause machine damage.
NOTE emphasizes essential information.

SAFETY

GENERAL POWER TOOL SAFETY WARNINGS
WARNING
Read all safety wamings and all instructions.
Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

1. Work area safety
   a) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
   b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust.
   Power tools create sparks which may ignite the dustor fumes.
   c) Keep children and bystanders away while operating a power tool.
   Distractions can cause you to lose control.

2. Electrical safety
   a) Power tool plugs must match the outlet.
   Never modl?yt e plug in any way.
   Do not use any adapter plugs with earthed (grounded) power tools.
   Unmodified plugs and matching outlets will reduce risk of electric shock.
   b) 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.
   c) Do not expose power tools to rain or wet conditions.
   Water entering a power tool will increase the risk of electric shock.
   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.
   d) 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.
   e) If operating a power tool in a damp location is unavoidable, use a residual current device HCD’ protected supply.
   Use of an RCD reduces the risk of electric shock.

3. Personal safety
   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.
   b) Use personal protective equipment. Always wear eye protection.
   e) Protective equipment such as dust mask, non-skid saley shoes, hard hat, or heannfl protection used for appropriate conditions reduce personal injuries.
   Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool.
   Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
   Remove any adjusting key or wrench before turning the power tool on.
   Awrench or a key left attached to a rotating part of the power tool may result in personal injury.
   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 jewellery. Keep your hair, clothing and gloves away from moving parts.
   Loose clothes, jewellery or long hair can be caught in moving parts.
   g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used.
   Use of dust collection can reduce dust-related hazards.

4. Power tool use and care
   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.
   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.
   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.
   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.
   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.
   Keep cutting tools sharp and clean.
   Properly maintained cumn? tools with sharp cutting edges are less likely to bind and are easier to control.
   Usethe 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.

5. Service
   a) Have your power tool serviced by a qualified repair person using only identical replacement s,
   This will ensure that the safety of the power tool is maintained.

SAFETY WARNINGS COMMON FOR GRINDING OPERATIONS

a) This power tool is intended to function as a grinder.
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) Operations such as sanding, wire brushing, gglishing or cutting-off are not recommended to performed with this power tool.
Operations for which the power tool was not designed may create a hazard and cause personal injury.
c) 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.
d) 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.
e) The outside diameter and the thickness of your accessory must be within the capacity rating of your power tool.
f) Incorrectly sized accessories cannot be adequately uarded or controlled.
hreaded mounting of accessories must match the grinder spindle thread. For accessories mounted by flanges, the arbour hole of the accessory must fit the locating diameter of the flange.

SAFETY WARNINGS SPECIFIC FOR GRINDING OPERATIONS

a) Use only wheel types that are recommended for your power tool and the specific guard designed for the selected wheel.
Wheels for which the power tool was not designed cannot be adequately guarded and are unsafe.
b) The grinding surface of center depressed wheels must be mounted below the plane of the guard lip. An improperly mounted wheel that projects through the plane of the guard lip cannot be adequately protected.
c) The guard must be securely attached to the power tool and positioned for maximum safety, so the least amount of wheel is exposed towards the operator.
The guard helps to protect the operator from broken wheel fragments, accidental contact with wheel and sparks that could ignite clothing.
d) Wheels must be used only for recommended applications. For example: do not grind with the side of cut-off wheel.
Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.
e) Always use undamaged wheel flanges that are of correct size and shape for your selected wheel.
Proper wheel flanges support the wheel thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be different from grinding wheel flanges.
f) Do not use wom down wheels from larger power tools.
Wheelintended for larger power tool is not suitable for the higher speed of a smaller tool and may burst.

GENERAL SAFETY INSTRUCTIONS FOR GRINDERS

• Check that speed marked on the wheel is equal to or Erealer than the rated speed of the grinder;
• Ensure that the wheel dimensions are compatible with the grinder;
• Abrasive wheels shall be stored and handled with care in accordance with manufacturer’s instructions;
• Inspect the grinding wheel before use, do not use chipped, cracked or otherwise defective products;
• Ensure that mounted wheels and points are fitted in accordance with the manufacturer’s instructions;
• Ensure that blotters are used when they are provided with the bonded abrasive product and when they are required;
• Ensure that the abrasive product is correctly mounted and tightened before use and run the tool at no- load for 30 s in a safe position, stop immediately if there is considerable vibration or if other defects are detected. If this  condition occurs, check the machine to determine the cause;
• If a guard is equipped with the tool never use the tool without such a guard;
• Do not use separate reducing bushings or adapters to adapt large hole abrasive wheels;
• Fortools intended to be fitted with threaded hole wheel, ensure that the thread in the wheel is long enough to accept the spindle length;
• Secure the workpiece and check that the workpiece is properly supported. A workpiece clamped with clamping devices or in a vice is held more securely than by hand;
• Donotuse cumn%(o“ wheel for side grinding;
• Ensure that sparks resulting from use do not create a hazard e.g. do not hit persons, or ignite flammable substances;
• Ensure that ventilation openings are kept clear when working in dusty conditions, if it should become necessary to clear dust, first disconnect the tool from the mains supply (use non metallic objects) and avoid damaging internal  parts;
• Always use eye and ear protection. Other personal protective equipment such as dust mask, gloves, helmet and apron should be worn;
• Pay attention to the wheel that continues to rotate after the tool is switched off.

SPECIFIC SAFETY RULES AND SYMBOLS

1. ALWAYS use proper guard with grinding 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 accessories running over rated speed can fly apartand cause injury.

3. ALWAYS wear ear protectors when using the tool for extended periods. Prolonged exposure to high intensity noise can cause hearing loss.

4. Use only a depressed center wheel with a rated capacity which is GREATER than 13,300/min. Using any wheel a rated capacity LESS than 13,300/min and/or an incorrect sized wheel (see SPECIFICATIONS at Fage 9) may result in  wheel breakage, flying wheel fragments, and resulting in death or serious injury.

5. NEVER touch moving parts.
   NEVER place your hands, fingers or other bo;/ parts near the tool’s moving parts.

6. NEVER operate without all guards in place.
   NEVER operate this tool without all guards or safety features in place and in proper working order. If maintenance or servicing requires the removal of a guard or safety feature, be sure to replace the guard or safety feature before resuming operation of the tool.

7. Use right tool.
   Don’t force small tool or attachment to do the job of a heavy-duty tool.
   Don’t use tool for purpose not intended —for example— don’t use circular saw for cutting tree limbs or logs.

8. NEVER use a power tool for applications other than those specified.
   NEVER use a power tool for applications other than those specified in the Instruction Manual.

9. Handle tool correctly.
   Operate the tool according to the instructions provided herein. Do not drop or throw the tool.
   NEVER allow the tool to be operated by children, individuals unfamiliar with its operation or unauthorized personnel.

10. Keep all screws, bolts and covers tightly in place.
    Keep all screws, bolts, and plates tightly mounted. Check their condition periodically.

11. Do not use power tools if the plastic housing or handle is cracked.
    Cracks in the tool’s housing or handle can lead to electric shock. Such tools should not be used until repaired.

12. Blades and accessories must be securely mounted tothe tool.
    Prevent potential injuries to yourself or others.
    Blades, cutting implements and accessories which have been mounted to the tool should be secure and tight.

13. Keep motor air vent clean.
    The tool’s motor air vent must be kept clean so that air can freely flow at all times. Check for dust build-up frequently.

14. Operate power tools at the rated voltage.
    Operate the power tool at voltages specified on its nameplate.
    If using the power tool at a higher voltage than the rated voltage, it will result in abnormally fast motor revolution and may damage the unit and the motor may burn out.

15. NEVER use a tool which is defective or operating abnormally.
    If the tool appears to be operating unusually, making strange noises, or otherwise appears defective, stop using it immediately and arrange for repairs by a metabo HPT authorized service center.

16. NEVER leave tool running unattended.
    Turn ower off. leave tool until it comes to acomplete stop.

17. Carefully handle power tools.
    Should a power tool be dropped or struck against hard materials inadvertently, it may be deformed, cracked, or damaged.

18. Do not wipe plastic parts with solvent.
    Solvents such as gasoline, thinner benzine, carbon tetrachloride, and alcohol may damage and crack plastic parts. Do not wipe them with such solvents. Wipe plastic parts with a soft cloth lightly dampened with soapy water and dry thoroughly.

19. NEVER use a depressed center wheel which is cracked or deformed or worn away (see the MAINTENANCE AND INSPECTION section on page 12)

20. NEVER use the grinder in places where the sparks generated by the ?nnder can cause explosion, such as where flammable materials or gases are present.

21. NEVER push in the push button while the spindle is running.

22. ALWAYS wear eye protection that meets the requirement of the latest revision of ANSI Standard 287.1.

23. ALWAYS wear a mask or respirator to protect yourself from dust or potentially harmful particles generated during the grinding operation.

24. ALWAYS firmly grip the body handle and side handle while operating the grinder.

25. ALWAYS have a trial run before grinding commence. (see Test the grinder before using on page 10).

26. ALWAYS follow the instructions contained in this manual when replacing the depressed center wheel.

27. ALWAYS be careful with buried object such as an underground wiring.
    Touching these active wiring or electric cable with this tool, you may receive an electric shock. Confirm if there are any buried object such as electric cable within the wall, floor or celling where you are going to operate here after.

28. Definitions for symbols used on this tool

V………….. volts
iv……………….. Alternating current
Hz………… hertz
A………….. amperes
n………….. rated speed
W…………. watt
****……….. Class II Construction
—/min…….. revolutions per minute
0…………… wheel diameter

DOUBLE INSULATION FOR SAFER OPERATION
To ensure safer operation of this power tool, metabo HPT has adopted a double insulation design. “Double insulation” means that two physically separated insulation systems have been used to insulate the electrically conductive materials connected to the power supply from the outer frame handled by the operator. Therefore, either the symbol “[a] ” or the words ‘Double insulation” appear onthe power tool oron the nameplate.
Although this system has no external grounding, you must still follow the nomal electrical safety precautions given in this Instruction Manual, including not using the power tool in wetenvironments.
To keep the double insulation system effective, follow these precautions:

SAVE THESE INSTRUCTIONS AND MAKE THEM AVAILABLE TO OTHER USERS AND OWNERS OF THIS TOOL!

FUNCTIONAL DESCRIPTION

NOTE
The information contained in this Instruction Manual is designed to assist you in the safe operation and maintenance of the power tool.
NEVER operate, or attempt any maintenance on the tool unless you have first read and understood all safety instructions contained in this manual.
Some illustrations in this Instruction Manual may show details or attachments that differ from those on your own power tool.

NAME OF PARTS

SPECIFICATIONS

Wheel Size:
external diam.
thickness
hole diam.| 4-1/2″ (115 mm)
1/4″ (6 mm)
7/8″ (22.23 mm)
Weight| 4.0 lbs (1.8 kg)

ASSEMBLY AND OPERATION

APPLICATIONS

• Removal of casting fin and finishing of various type of steel, bronze and aluminum materials and castings.
• Grinding of welded sections or sections cut by means of an acetylene torch.

WARNING
To avoid the risk of serious injury, NEVER use this grinder with cup wheels and/or saw blades.

PRIOR TO OPERATION

1. Power source Ensure that the power source to be ufilized conforms to the power source requirements specified on the roduct nameplate.

2. Power switch
   Ensure that the switch is in the OFF position. If the plug is connected to a receptacle while the switch is inthe ON Fosmon, the power tool will start operating immediately and can cause serious injury.

3. Extension cord
   When the work area is far away from the power source, use an extension cord of sufficient thickness and rated capacity. The extension cord should be kept as short as practicable.
   WARNING
   Damaged cord must be replaced or repaired.

4. Checkthe receptacle
   If the receptacle only loosely accepts the F\ug, the receptacle must be repaired. Contact a licensed electrician to make appropriate repairs.
   If such a faulty receptacle is used, it may cause overheating, resiting in a serious hazard.

5. Check your work environment
   Ensure the following before operation;
   Noflammable gas, liquid, or object at worksite.
   When grinding thin steel sheet it may cause a high booming noise.
   To avoid such noise, place a rubber mat under the workpiece.
   Clear the area of children or unauthorized personnel.

6. Mounting the wheel guard
   Be sure to mount the wheel guard at an angle that will protect the operator’s body from injury by a broken wheel piece.
   [Installing Wheel Guard] Slightly loosen the screw on the wheel guard.
   Install’the wheel guard to the packing gland, tumn it to the angle suitable for operation, and make adjustment.
   After the adjustment, ensure that the screw is securely tightened on the wheel guard in order to fix it completely. WARNING
   If the wheel guard is not attached properly, a broken wheel may result in and cause death or serious injury.

7. Thoroughly check that the depressed center wheel is free of cracks, splits and other abnormalities before mounting. Make sure it is firmly clamped and has been properly mounted. Refer to page 11 of this manual for Depressed  Center Wheel Assembly and Disassembly

8. Testthe grinder before using.
   Before actually beginning the grinding work, test the grinder by first clearing the area of all other personnel. Make sure the wheel guard is in place and that you are wearing eKe protection. Turn the grinder “on”, and make sure the  grinder runs smoothly and shows no abnormalities.
   Duration of the trial run is as follows:

9. Use only properly chenter wheels.
   Use only depressed center wheels rated at 13,300/min or more.
   Using a depressed center wheel rated less can lead to wheel disintegration during operation and cause serious bodily injury.

10. Check the push button.
    Make sure that the push button is disengaged by pushing push button two or three times before turning onthe grinder. (Fig. 5)

GRINDER OPERATION

1. Hold the grinder firmly by its housing and side handle (Fig.1).
   The grinder produces a counterforce which must be controlled by firmly holding onto the grinder.
   Turn the grinder “on”. (Fig. 3)While holding the grinder firmly, use one finger to slide the switch to the “on” position.

2. Use light grinding pressure.
   There is no need to press hard when grinding.
   Usually the grinder’s own weight is sufficient to allow the required light contact with the surface to be ground.
   WARNING

3. Do not press the grinder forcibly against the surface to be ground. Heavy pressure can result in wheel breakage and serious injury. It can also damage the surface being ground or damage the grinder’s motor.
   Use proper grinding angle.

4. Grind only with the wheel’s edge by lifting the grinder 15°to 30°, as shown in Fig. 4.
   CAUTION
   Do not use the entire surface of the depressed center wheel. Use only the edge of the depressed center wheel.
   Move the grinder in the proper direction.

5. When using a new depressed center wheel in direction A (Fig. 4), the wheel edge may cut into the workpiece. Inthis case, grind in direction B (Fig. 4). Once the wheel edge is worn, the workpiece can be ground in both directions.
   NOTE
   The wheel provided (resinoid wheel) is rated as Class A grain and # 36 grain size. It is most suitable for heavy grinding of steel and other types of materials.

6. Adjust operation to desired finish.
   For a fine finish, decrease pressure by lifting slightly.
   Grind slowly and at the appropriate speed.
   CAUTION
   The revolving depressed center wheel will create air turbulence.
   Do nolay the grinder down in areas of dust or dirt until it has come to a complete stop.

DEPRESSED CENTER WHEEL ASSEMBLY AND DISASSEMBLY

WARNING
Never attempt to assemble or disassemble the depressed center wheel, unless the power switch is in the “OFF” position and the electrical cord has been disconnected from the receptacle.
Assembly
Tumn the disc grinder upsidedown so that the spindle Align the oval-shaped indentation of the wheel washer with the notched part of the spindle, then attach them.
Fit the protuberance of the depressed center wheel onto the wheel washer.
Screw the wheel nut onto the spindle.
While pushing the push button with one hand, lock the spindle by tuming the depressed center wheel slowly with the other hand.
Tighten the wheel nut by using the supplied wrench as shown in Fig. 5.

CAUTION
Tighten the wheel nut securely and confirm that the depressed center wheel does not wobble.
Disassembly
To remove the depressed center wheel, simply reverse the above-mentioned procedure.

MAINTENANCE AND INSPECTION

WARNING

• Be sure to switch power OFF and disconnect the plug from the receptacle during maintenance and inspection.
• Using cracked, deformed or damaged wheels can lead to wheel breakage and resulting serious injury.

1. Replacing the depressed center wheel Replace the depressed center wheel when it has been wom out to about 2-3/8″ (60 mm) in external diameter. Confirm that there is no crack or any damage to the depressed center wheel. If  there is a crack ora transformation in the wheel, replace it immediately.

2. Inspecting the screws
   Regularly inspect all screws and ensure that they are fully tightened. Should any of the screws be loosened, retighten them immediately.
   WARNING
   Using this grinder with loosened screws is extremely dangerous.

3. Confirm that there is no damage in the wheel guard, the electrical cord and the housing, etc.
   Check that the on/off switch operates normally.

4. Inspecting the carbon brushes
   For your continued safety and electrical shock protection, carbon brush inspection and replacement on this tool should ONLY be performed by a metabo HPT AUTHORIZED SERVICE CENTER.

5. Replacing supply cord
   If the supply cord of Tool is damaged, the Tool must be returned to metabo HPT Authorized Service Center for the cord to be replaced.

6. Service and repairs
   All quality power tools will eventually require servicin or replacement of parts because of wear from normal use. To assure that only authorized replacement parts will be used, all service and repairs must performed by a metabo HPT AUTHORIZED

7. SERVICE CENTER, ONLY.
   Maintenance of the motor

WARNING
Always wear protective goggles and dust respirators when blowing air from the tail cover air hole with the use of an airgun, etc.
Failure to observe this may result in ejected dust being inhaled or entering your eyes.
The coil on the motor is an important part of the unit.
Make sure that it is not damaged or subject to oil or water.

ACCESSORIES

WARNING
Never use any accessories other than those mentioned below.
The use of any accessories other than those mentioned below or attachments not intended for use such as cup wheel, cut-off wheel or saw blade is dangerous and may cause personal injury or property damage.

STANDARD ACCESSORIES

• Depressed center wheel (Code No. 316821)…………1
  4-1/2″ (115 mm) external dia. x 1/4″ (6 mm) thickness x 7/8″ (22.23 mm) hole dia.

• Wrench (Code No. 9383:

• Side Handle (Code No. 318312).

NOTE
Specifications are subject to change without any obligation on the part of the metabo HPT.

WARNING:
Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of 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 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 ventilated area, and work with approved safety equipment, such as those dust  masks that are specially designed to filter out microscopic particles.

Issued by
Koki Holdings Co., Ltd.
Shinagawa Intercity Tower A, 15-1, Konan 2-chome,
Minato-ku, Tokyo 108-6020, Japan
Distributed by
Koki Holdings America Ltd.
1111 Broadway Ave,
Braselton, Georgia, 30517
Koki Holdings America Ltd. Canadian Branch
3405 American Drive, Units 9-10,
Mississauga, ON, L4V 1T6
806
Code No.C99714062 NA
Printed in China

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