RUPES HLR21 Polisher Instruction Manual

RUPES HLR21 Polisher

WARNING: For your personal safety, READ and UNDERSTAND the instruction manual before using
SAVE THESE INSTRUCTIONS. VEUILLEZ CONSERVER CES INSTRUCTIONS CONSERVE ESTAS INSTRUCCIONES

EXPLANATION OF SIGNAL WORD

WARNING : Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury and/ or property damage.
CAUTION : Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury and/or property damage.
NOTICE : Indicates a potentially hazardous situation, which, if not avoided, may result in property damage.

GENERAL POWER TOOL SAFETY WARNINGS

WARNING! 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. 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 a 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 energising 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 jewellery. Keep your hair and clothing 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.
   • h ) Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.
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 remove the battery pack, if detachable, 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 and accessories. 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.
   • 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.
   • h ) Keep handles and grasping surfaces dry, clean and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
5. Battery tool use and care
   • a ) Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack.
   • b ) Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire.
   • c ) When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire.
   • d ) Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns.
   • e ) Do not use a battery pack or tool that is damaged or modified. Damaged or modified batteries may exhibit unpredictable behaviour resulting in fire, explosion or risk of injury.
   • f ) Do not expose a battery pack or tool to fire or excessive temperature. Exposure to fire or temperature above 130°C may cause explosion.
   • g ) Follow all charging instructions and do not charge the battery pack or tool outside the temperature range specified in the instructions. Charging improperly or at temperatures outside the specified range may damage the battery and increase the risk of fire.
6. Service
7. 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.
8. Never service damaged battery packs. Service of battery packs should only be performed by the manufacturer or authorized service providers.

ADDITIONAL SAFETY INSTRUCTIONS

1. This tool is designed to be used as a polisher. Read all the warnings, instructions, indications provided on drawings and specifications supplied with this tool. Failure to comply with all the instructions provided may cause electrical shocks, fire and/or serious injuries.
2. This tool is not intended to be used for smoothing, metal brushing and cutting operations. The use of this tool for unintended applications may cause hazards and injuries to people.
3. The tool must be used with accessories that have been specifically designed or recommended by the manufacturer. The fixing of the accessory to the tool does not guarantee a safe operation; read the following additional instructions.
4. The rated speed of the accessories must be at least equivalent to the maximum speed specified on the tool. Using the accessories at speeds above the rated one, may cause them to break or be projected into the air.
5. The external diameter and thickness of the accessories must match the specifications of the tool. Accessories with incorrect dimensions cannot be adequately protected or controlled.
6. The configuration of accessories must match the tool. The use of accessories that cannot be perfectly fitted on the too may result in imbalance, excessive vibrations and in the impossibility of controlling the tool.
7. Do not use damaged accessories. Before use, inspect all the accessories. Inspect the supporting pads and verify there are no cracks, tears or excessive wear. If the tool or accessory has fallen, verify that they are not damaged or install a new accessory. After inspecting or installing an accessory, test the operation of the tool at maximum speed and without load for one minute, keeping at a safety distance. If the accessories are damaged, they will break during this test.
8. 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.
9. 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.
10. 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.
11. 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.
12. 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.
13. 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.
14. Do not operate the power tool near flammable materials. Sparks could ignite these materials.
15. Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

Further Safety Instructions for All Operations – KICKBACK AND RELATED WARNINGS
Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, brush or anyother 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 at the point of the binding.

For example, if a polishing mop is snagged or pinched by the workpiece, the edge of the mop that is entering into the pinch point can dig into the surface of the material causing the mop to climb out or kick out.The mop may either jump toward or away from the operator, depending on direction of the mop’s movement at the point of pinching. Polishing mops may also break under these conditions.

Kickback is the result of tool misuse and/or incorrect operating procedures or conditions and can be avoided by taking proper precautions as given below:

1. Maintain a firm grip on the power tool and position your body and arm to allow you to resist kickback forces. Always use auxiliary handle, if provided, for maximum control over kickback or torque reaction during start up. The operator can control torque reaction or kickback forces, if proper precautions are taken.
2. Never place your hand near the rotating accessory. Accessory may kickback over your hand.
3. Do not position your body in the area where power tool will move if kickback occurs. Kickback will propel the tool in direction opposite to the wheel’s movement at the point of snagging.
4. 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.
5. Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickback and loss of control.

Additional Specific Safety Instructions for Polishers

• Always use eye protection. All users and bystanders must wear eye protection that conforms to ANSI Z87.1.
• Clean out your tool often, especially after heavy use. Dust and grit containing metal particles often accumulate on interior surfaces and could create an electric shock hazard.
• Do not operate this tool for long periods of time. Vibration caused by the operating action of this tool may cause permanent injury to fingers, hands and arms. Use gloves to provide extra cushion, take frequent rest periods and limit daily time of use.
• Air vents often cover moving parts and should be avoided. Loose clothes, jewelry or long hair can be caught in moving parts. 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.
• Avoid prolonged contact with dust from polishing. Wear protective clothing and wash exposed areas with soap and water. Allowing dust to get into your mouth, eyes, or lay on the skin may promote absorption of harmful chemicals.

• WARNING : Always use safety glasses. Everyday eyeglasses are NOT safety glasses. Also use face or dust mask if cutting operation is dusty.
• ALWAYS WEAR CERTIFIED SAFETY EQUIPMENT:
  • ANSI Z87.1 eye protection (CAN/CSA Z94.3),
  • ANSI S12.6 (S3.19) hearing protection,
  • NIOSH/OSHA/MSHA respiratory protection.
• WARNING : Always wear proper personal hearing protection that conforms to ANSI S12.6 (S3.19) during use. Under some conditions and duration of use, noise from this product may contribute to hearing loss.
• WARNING : Some dust created by polishing 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,
  • arsenic and chromium from chemically-treated
• WARNING : Use of this tool can generate and/or disperse dust, which may cause serious and permanent respiratory or other injury. Always use NIOSH/OSHA approved respiratory protection appropriate for the dust exposure. Direct particles away from face and body.
• CAUTION : Use extra care when working into a corner because a sudden, sharp movement of the polisher may be experienced when the polishing mop or other accessory contacts a secondary surface or a surface edge

TECHNICAL DATA

• The value is referred to a use of the battery pack 9HB185LT, fully charged with the charger 9HC185LT.
• Measured with all attachments needed for normal use, but without power units: battery pack or power supply.

INTENDED USE
The HLR21 and HLR15 heavy-duty polishers is designed for polishing painted or unfinished metal, fiberglass, and composite surfaces in professional applications. Common examples of use include but are not limited to: auto/marine/RV/motorcycle detailing and finish correction, boat construction and repair, and metal finishing. Do not use in the presence of flammable liquids or gases. Do not let children come into contact with the tool. Supervision is required when inexperienced operators use this tool.

PARTS OF THE TOOL

1. Identification plate
2. Speed regulation wheel
3. Variable actuation switch lever
4. Backing pad
5. Battery pack 9HB185LT
6. Power supply 9HP185LT
7. Backing pad screw
8. Lock button
9. Light
10. Allen wrench

STARTING UP
WARNING : to reduce the risk of injury, only the 18V Li-Ion battery pack 9HB185LT (5) or the power supply 9HP185LT (6) should be used with this product. Since the batteries other than those offered by RUPES have not been tested with this product, use of such batteries with this tool could cause injury and property damage.

BATTERY PACK (PROVIDED OR OPTIONAL)

• WARNING : for your personal safety, READ and UNDERSTAND the instruction manual of the battery pack 9HB185LT before using.
• WARNING : avoid short circuiting the contacts. Avoid mechanical damage of the battery pack. Do not open or disassemble. Advice on protection against fire and explosion. Keep away from open flames, hot surfaces and sources of ignition.

Temperature in excess of 45°C reduce the performance of the battery pack. Avoid extended exposure to heat or sunshine. Storage at room temperature (approx. 20°C) at approx. 20-60% of the nominal capacity. Every six months of storage, charge the battery pack as normal.

Intended use
The battery pack 9HB185LT (5) is used as the power source for RUPES tools HLR21-HLR15.

Battery pack specifications:

Model| Chemistry| Voltage| Capacity| Energy| Weight
---|---|---|---|---|---
9HB185LT| Lithium Ion| 18V| 5.0 Ah| 90 Wh| 0.655 ± 0.005 kg

WARNING : for other technical data refer to the label of battery pack 9HB185LT.
WARNING : to reduce the risk of injury or explosion, never burn or incinerate a tool’s battery pack even if it is
damaged, dead or completely discharged. When burned, toxic fumes and materials are created.
CONNECT AND DISCONNECT THE BATTERY PACK
WARNING : before (dis)connecting the battery pack to the tool assure that the variable actuation switch lever (3) is released and locked (tool switched off).
In order to connect the battery pack, push the clip and insert the battery pack in the tool till it is fixed; the light fade-in for about 3
seconds and then fade-out to indicate that the tool is correctly powered. In order to disconnect push the clip and extract the battery from the tool.

CHARGE THE BATTERY PACK

WARNING : for your personal safety, READ and UNDERSTAND the instruction manual of charging station 9HC185LT before using.

WARNING : charge Rupes 18V Li-Ion battery pack 9HB185LT only in the Rupes 18V Li-Ion battery charger 9HC185LT. Other types of batteries may cause personal injury and damage. This tool’s battery pack and charger are not compatible with NiCd or NiMH systems.

The battery pack(s) contained in the kit shall be charged before use. The provided battery packs are charged <30%. In order to charge, connect the Li- Ion battery with the battery charger 9HC185LT till the charging is completed. Charge the battery pack of your tool when it’s convenient for you and your job. The Rupes battery pack does not develop “memory” when charged after only a partial discharge. It is not necessary to run down the tool’s battery pack before placing it onto the battery charger. Use the led level indication of the battery pack 9HB185LT to determine when to charge the Rupes battery pack.

POWER SUPPLY (PROVIDED OR OPTIONAL)
WARNING : for your personal safety, READ and UNDERSTAND the instruction manual of power supply  9HP185LT before using.

WARNING : voltage and power frequency must match the data displayed on the identification plate of the power supply 9HP185LT. Make sure that tool is switched off before connecting the plug.

CONNECT AND DISCONNECT THE POWER SUPPLY
WARNING : before (dis)connecting the power supply to the tool assure that the variable actuation switch lever (3) is released and locked (tool switched off). In order to connect the power supply, push the clip and insert the power supply in the tool till it is fixed; the light fade-in for about 3 seconds and then fade-out to indicate that the tool is correctly powered. In order to disconnect, push the clip and extract the power supply from the tool.

STARTING AND STOPPING

• Starting : the tool can be started by pressing the lock button (8) on the left side and the speed regulation wheel (3). The speed can be adjusted in two ways: by means of the variable actuation switch lever (3) and by means of the speed regulation wheel (2) fitted on the upper part of the machine. Adjustment by means of the wheel (2) affects the adjustment made using the variable actuation switch (3), determining the maximum speed of the motor. The speed must be selected according to the characteristics of the pads and those of the material to be machined.
• Stopping : release the lever (3) for stopping the tool; the tool is now switched off.
• WARNING : in case of unusual vibration after a start of the tool, switch-off the tool immediately and eliminate the fault.
• WARNING : to reduce the risk of injury, release the lever to stop the tool after the use.

ELECTRONIC CONTROLLER

Soft start
The soft start is electronically controlled. The soft start guarantees the motor and battery pack protection and reduces the risk of injury for the operator.

Speed control
The maximum speed of the tool can be changed by rotating the speed regulation wheel (2) to the desired setting between 3000 (speed 1) and 4200/5000 (speed 6) RPM.

Light indications (9)

• Fading : when the battery pack is inserted or when the tool is connected to the mains via the power supply 9HP185LT, the light fade-in for about 3 seconds and then fade-out to indicate that the tool is correctly powered;
• Variable intensity : during use, the light intensity varies with the speed of the tool;
• Slow flashing : low battery warning;
• Fast flashing : overload.

Tool protections
The electronic protection protects the tool from different events that can damage the tool and create a risk of injury for the operator. It also guarantees a longer life.
NOTICE : in case of overcurrent or overheating caused by repeated starts or excessive overloads, the protection limits the tool power consumption and reduce RPM. If the condition persists, the electronic protection turns off the tool.

ACCESSORIES ASSEMBLY AND DISASSEMBLY

WARNING : before (dis)assembling the accessories with the tool assure that the variable actuation switch lever (3) is released and locked (tool switched off).
NOTICE : for optimal tool performance use only original accessories and consumables.

Backing Pad

• Place the backing pad (4) in the center; slightly turn the backing pad until it is in the correct position on the spindle (Fig. 1);
• Tighten the backing pad fixing screw (7) using the Allen wrench (10) (Fig. 2);
• For disassembly: unscrew pad’s mounting screw (7) using the wrench (10) (Fig. 3).

NOTICE : the fitting of non-original or incorrect sized backing pads may cause excessive vibration of the tool.

Polishing Foam

• Used polishing pad can be removed by simply tearing them off;
• Apply the new polishing pad by pressing the same on the backing pad.
• NOTICE: only Ø 180-150 mm polishing foam for backing pad Ø150-125 mm are allowed.

MAINTENANCE AND SERVICING

WARNING : all maintenance operations must be performed with the power disconnected. Make sure to remove the power supply 9HP185LT or the battery pack 9HB185LT from the tool and that the switch is released and locked (tool switched off).

CLEANING
At the end of each work session, or when required, remove any dust from the body of the tool using a soft cloth, paying particular attention to the motor ventilation slots. No other maintenance operations must be undertaken by the user.

REPAIRS
Maintenance and cleaning of the inner parts like ball bearings, gears etc. or others, must be carried out only by an authorized customer service workshop.

WARRANTY

Complying with current applicable regulations and subject to more favorable conditions that could apply in different countries, RUPES professional tools are supplied with a 12 months warranty against manufacturing defects from date of purchase. Only Rupes original parts and accessories must be employed with RUPES tools. Rupes is not responsible for any damages or accidents caused by not abiding to this rule and the warranty shall terminate if non-original parts are employed. Damages caused by natural wear and tear, overloading, faulty maintenance and tool usage differing from the one specified in the user guide, are not covered by this warranty. A tool which has been proven faulty must be delivered to an authorized Rupes service center along with its fully filled out warranty certification and document of purchase. Warranty shall be void if tool should be delivered disassembled or tampered. This warranty does not in any way imply tool’s replacement. RUPES SpA reserves the right to make specifications or design changes to its products without further notice. RUPES does not accept any responsibility for any possible printing mistake. This document supersedes all previously printed one.

FREE LABEL REPLACEMENT: If your labels become illegible or are missing, cal 0039 02 94 694 1 RUPES S.p.A. for a free replacement.

RUPES S.p.A.
Via Marconi, 3/A – Loc. Vermezzo
20071 Vermezzo con Zelo (MI) – Italy
Tel. +39 02 946941
Fax +39 02 94941040
[email protected]
www.rupes.com
Registered Office:
Viale Bianca Maria, 13 – 20122 MILANO – ITALY.

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