HiKOKI GP 2S2 Direct Sander Instructions

GP 2S2 Direct Sander

Handling instructions

(Original instructions)

GENERAL POWER TOOL SAFETY WARNINGS

WARNING
Read all safety warnings and all instructions.
Failure to follow the warnings and instructions may result in
electric shock, fi re 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 dust
or 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 modify the 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.
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 residual current device
(RCD) 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.
Protective equipment such as dust mask, non-skid
safety shoes, hard hat, or hearing protection used for
appropriate conditions will reduce personal injuries.

c) 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 energizing power tools that have the switch on
invites accidents.
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.
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.
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
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.
b) 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.
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.
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 tools operation.
If damaged, have the power tool repaired before use.
Many accidents are caused by poorly maintained
power tools.
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.
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.

5) Service
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.

PRECAUTION
Keep children and infirm persons away.
When not in use, tools should be stored out of reach of
children and infirm persons.

SAFETY WARNINGS COMMON FOR GRINDING OPERATIONS

a) This power tool is intended to function as a grinder.
Read all safety warnings, instructions, illustrations
and specifi cations provided with this power tool.
Failure to follow all instructions listed below may result in
electric shock, fi re and/or serious injury.
b) Operations such as sanding, wire brushing,
polishing or cutting-off are not recommended to be
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 specifi cally
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 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 fl y apart.
e) 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.
f) The arbour size of wheels, sanding drums or any
other accessory must properly fi t 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.
g) Mandrel mounted wheels, sanding drums, cutters
or other accessories must be fully inserted into the
collet or chuck.
If the mandrel is insuffi ciently held and/or the overhang
of the wheel is too long, the mounted wheel may become
loose and be ejected at high velocity.
h) Do not use a damaged accessory. Before each us
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.
i) 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.
j) 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.

k) 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.
l) Always hold the tool fi rmly in your hand(s) during
the start-up.
The reaction torque of the motor, as it accelerates to full
speed, can cause the tool to twist.
m) 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
hand(s) 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.
n) 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.
o) 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.
p) After changing the bits or making any adjustments,
make sure the collet nut, chuck or any other
adjustment devices are securely tightened.
Loose adjustment devices can unexpectedly shift,
causing loss of control, loose rotating components will
be violently thrown.
q) 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.
r) Regularly clean the power tool’s air vents.
The motor’s fan will draw the dust inside the housing and
excessive accumulation of powdered metal may cause
electrical hazards.
s) Do not operate the power tool near flammable materials.
Sparks could ignite these materials.
t) Do not use accessories that require liquid coolants.
Using water or other liquid coolants may result in
electrocution or shock.

KICKBACK AND RELATED WARNINGS

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 given below.
a) Maintain a fi rm 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 fi les, cut-off wheels, high-speed
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 fi le,
high-speed cutter or tungsten carbide cutter grabs, it
may jump from the groove and you could lose control of
the tool.

SAFETY WARNINGS SPECIFIC FOR GRINDING 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.

GENERAL SAFETY INSTRUCTIONS FOR GRINDERS

– Check that speed marked on the wheel is equal to or
greater 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 fi tted 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 seconds 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;
– For tools intended to be fitted with threaded hole wheel,
ensure that the thread in the wheel is long enough to
accept the spindle length;
– Check that the work piece is properly supported;
– Do not use cutting off 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 .

ADDITIONAL SAFETY WARNINGS

1. Ensure that the power source to be utilized conforms
to the power requirements specified on the product
nameplate.
2. Ensure that the power switch is in the OFF position. If the
plug is connected to a receptacle while the power switch
is in the ON position, the power tool will start operating
immediately, which could cause a serious accident.
3. When the work area is removed from the power source,
use an extension cord of sufficient thickness and rated
capacity. The extension cord should be kept as short as
practicable.
4. Installing a wheel (Fig. 1)
○ Install the wheel so that length ℓ is less than 15 mm. If ℓ
is longer, abnormal vibration will occur, and the machine
is not only negatively affected, but there is a possibility of
a serious accident.
Make the ℓ as small as possible.
When d = 6 mm, 8 mm, D of the wheel should be less
than 25 mm. If a wheel with D more than 25 mm is used,
the circumference speed exceeds the safety limit and
the wheel will break. Never use such a wheel.
Distance L varies for D. Determine L referring to the table
below.
When d = 3 mm, D should be less than 10 mm. Determine
L referring to the table below.

Wheels can be simply attached and detached by using
the two wrenches. (Fig. 2)
○ Do not tighten the collet chuck by inserting a shaft thinner
than the regular shaft diameter (6 mm) in the chuck or in an
empty condition. This practice will damage the collet chuck.
○ When installing a wheel with shaft, tighten the collet
chuck after applying a small quantity of spindle oil (or
sewing machine oil) to the tapered portion indicated in
Fig. 2.
5. Be sure to use the side handle to avoid the risk of severe
electrical shock.
6. Lightly press the wheel to the material to be ground. When
grinding materials, high-speed revolution is necessary.
Use a hand grinder with high-speed revolution, minimizing
the pressing force.

7. Dressing the wheel

After attaching a wheel, correct deflection of the wheel
center by using a dresser. If the wheel center is eccentric,
not only precise finishing cannot be achieved but also
grinder vibration increases, lowering grinder accuracy
and durability.
A clogged or worn wheel will spoil the finishing surface or
lower grinding efficiency. Occasionally dress the wheel
by applying the dresser.

SYMBOLS

WARNING

The following show symbols used for the machine.
Be sure that you understand their meaning before
use.

|

GP2S2: Portable Grinder

---|---
|

Read all safety warnings and all instructions.

|

Always wear eye protection.

|

Only for EU countries
Do not dispose of electric tools together with
household waste material!
In observance of European Directive 2002/96/
EC on waste electrical and electronic equipment
and its implementation in accordance with
national law, electric tools that have reached
the end of their life must be collected separately
and returned to an environmentally compatible
recycling facility.

V| Rated voltage
~|

Alternating current

P| Power input
n| Rated speed
min-1|

Revolution or reciprocations per minute

| Switching ON
| Switching OFF
|

Disconnect mains plug from electrical outlet

| Warning
| Class II tool

STANDARD ACCESSORIES

In addition to the main unit (1 unit), the package
contains the accessories listed in the below.
(1) Wrench (17 mm) …………………………………………………..1
(2) Wrench (12 mm) …………………………………………………..1
(3) Side handle (Not included by areas) ………………………..1
Standard accessories are subject to change without notice.

APPLICATIONS

○ Finishing of dies for press working, die casting and Moulding.
○ Finishing of thread cutting dies, tools and other small parts.
○ Internal grinding of tools and machine parts.

SPECIFICATIONS

Voltage (by areas)*

|

(110 V, 120 V, 127 V, 220 V,  230 V, 240 V)

---|---

Power input*

|

 520 W

Rated speed*

|

 29000 min-1

Max. Wheel Diam.*

|

 25 mm

Collet chuck Capacity**

|

 6 mm

Weight (without cord)

|

 1.7 kg

• Be sure to check the nameplate on product as it is  subject to change by areas.

** This varies depending on the area.

NOTE

 Due to HiKOKI’s continuing program of research and  development, the specifications herein are subject to  change without prior notice.

MOUNTING AND OPERATION

Action

|

 Figure

|

 Page

---|---|---

Assembling a wheel

|

 2

|

 126

Fixing the side handle

|

3

|

 126

Changing a collet chuck

|

 4

|

 127

Switch operation

|

 5

|

 127

Replacing carbon brushes

|

 6

|

 127

Selecting accessories

|

―

|

128

WHEEL SELECTING METHOD

Types of wheels are varied according to the materials to be ground. Select a wheel appropriate for the material to be ground. The following table is an outline of wheels and materials to be ground.

Materials to be ground

|

 Grain

|

 Grading

|

Bonding degree

|

Structure

|

 Bonding agent

---|---|---|---|---|---

Mild steel, hard steel, forged  steel

|

WA

|

 60 − 80

|

 P

|

 m

|

 V

Cast iron

|

 C

|

 36

|

 M − O

|

m

|

 V

Brass, bronze, aluminium

|

 C

|

 36

|

 J − K

|

m

|

 V

Ceramic

|

 WA

|

 60 − 80

|

 M

|

 m

|

 V

Synthetic resin

|

 C

|

 36

|

 K − M

|

m

|

 V

Small-scaled wheels with shaft are prepared for grinding small surfaces. Their dimensions and shapes are shown in  “Selecting accessories”.

Since wheel shaft diameter is 3 mm, use the collet chuck for 3 mm shaft sold separately by your HiKOKI dealer as an  optional accessory.

MAINTENANCE AND INSPECTION

1. Inspecting the wheel

Ensure that the wheel is free of cracks and surface  defects.

2. Inspecting the mounting screws

Regularly inspect all mounting screws and ensure that  they are properly tightened. Should any of the screws be  loose, retighten them immediately. Failure to do so could  result in serious hazard.

3. Inspecting the carbon brushes (Fig. 6)

The motor employs carbon brushes which are  consumable parts. Since an excessively worn carbon  brush can result in motor trouble, replace the carbon brushes with new ones having the same carbon brush  No. ⓐ shown in the fi gure when it becomes worn to or  near the “wear limit” ⓑ. In addition, always keep carbon  brushes clean and ensue that they slide freely within the  brush holders.

4. Replacing carbon brushes