HiKOKI GP 3V Direct Sander Instruction Manual

GP 3V/GP 5V
Handling 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 the 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 fl flammable liquids, gases, or dust. Power tools create sparks that may ignite 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. Unmodifi end plugs and matching outlets will reduce the 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 the 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. The 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. The 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 infl uence 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 masks, non-skid safety shoes, hard hats, 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 a power source and/or battery pack, picking up or carrying the tool.
   Carrying power tools with your fi nger 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. The 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 aff ect the power tool 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 diff erent from those intended could result in a hazardous situation.

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

PRECAUTION
Keep children and infi rm persons away.
When not in use, tools should be stored out of reach of children and infi rm 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, or polishing 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 that 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 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 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 guarded or controlled.
f) Threaded mounting of accessories must match the grinder spindle thread. For accessories mounted by fl anges, the arbor hole of the accessory must fi t the locating diameter of the fl ange. Accessories that do not match the mounting hardware of the power tool will run out of balance, vibrate excessively, and may cause a loss of control.
g) Do not use a damaged accessory. Before each use inspects the accessory such as abrasive wheels for chips and cracks, a backing pad for cracks, tear, or excess wear, and a wire brush for loose or cracked wires. If a 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 the application, use a face shield, safety goggles, or safety glasses. As appropriate, wear a dust mask, hearing protectors, gloves, and a workshop apron capable of stopping small abrasive or workpiece fragments. The eye protection must be capable of stopping fl Ying debris generated by various operations. The dust mask or respirator must be capable of fi filtrating particles generated by your operation. Prolonged exposure to high-intensity noise may cause hearing loss.
i) Keep bystanders at a safe distance away from the work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpieces or of a broken accessory may fl y away and cause injury beyond the immediate area of operation.
j) Hold the 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) 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.
l) 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. m) 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.
n) 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.
o) Do not operate the power tool near fl flammable materials. Sparks could ignite these materials.
p) Do not use accessories that require liquid coolants. Using water or other liquid coolants may result in electrocution or shock.

KICKBACK AND RELATED WARNINGS

Kickback is a sudden reaction to a pinched or snagged rotating wheel, backing pad, 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 at the point of the binding.
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 the 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. Always use an auxiliary handle, if provided, for maximum control over kickback or torque reaction during start- up. The operator can control torque reactions or kickback forces if proper precautions are taken.
b) Never place your hand near the rotating accessory. The accessory may kick back over your hand.
c) Do not position your body in the area where the power tool will move if kickback occurs. Kickback will propel the tool in a direction opposite to the wheel’s movement at the point of snagging.
d) 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.
e) Do not attach a saw chain woodcarving blade or toothed saw blade. Such blades create frequent kickbacks and loss of control.

SAFETY WARNINGS SPECIFIC FOR GRINDING AND ABRASIVE CUTTING-OFF OPERATIONS

a) Use only wheel types that are recommended for your power tool and the specifi c 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 the 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) Wheels must be used only for recommended applications. For example: do not grind with the side of the cut-off wheel. Abrasive cut-off wheels are intended for peripheral grinding, side forces applied to these wheels may cause them to shatter.
d) Always use undamaged wheel fl anges that are of the correct size and shape for your selected wheel. Proper wheel fl anges support the wheel thus reducing the possibility of wheel breakage. Flanges for cut-off wheels may be diff erent from grinding wheel fl anges.
e) Do not use worn-down wheels from larger power tools. The wheel intended for larger power tools 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 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 the 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 tested 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 fi fitted with threaded hole wheel, ensure that the thread in the wheel is long enough to accept the spindle length;
• Check that the workpiece is properly supported;
• Do not use the 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 fl flammable substances;
• Ensure that ventilation openings are kept clear when working in dusty conditions, if it should become necessary to clear dust, fi first disconnect the tool from the mains supply (use nonmetallic objects) and avoid damaging internal parts;
• Always use eye and ear protection. Other personal protective equipment such as a dust mask, gloves, helmet, and apron should be worn;
• Pay attention to the wheel that continues to rotate after the tool is switched off.

SYMBOLS

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

| GP3V / GP5V: Electronic Hand 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.
| Rated voltage
Alternating current
Power input
No-load speed
Rated speed
Revolution or reciprocations per minute
Switching ON
Switching OFF
Disconnect the mains plug from the electrical outlet
Warning
Class II tool

STANDARD ACCESSORIES

In addition to the main unit (1 unit), the package contains the accessories listed in below.

• Wrench (17 mm) …………………………………………………..1
• Wrench (12 mm) …………………………………………………..1
• Side handle (Not included by areas) ………………………..1

Standard accessories are subject to change without notice.

APPLICATIONS

• Finishing of dies for press work, die casting, and molding.
• Finishing of thread-cutting dies, tools, and other small parts.
• Internal grinding of tools and machine parts.

SPECIFICATIONS

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

• This varies depending on the area.
  Electronic Control
  The grinder has an electronic speed control that provides:

  • full speed at all times in the range up to the rated load.
  • soft-start.
  • variable speed

NOTE
The grinder is equipped with a rotational speed control circuit. The rotational speed may fl actuate slightly due to the conditions of use and working voltage.
NOTE
Due to HiKOKI’s continuing program of research and development, the specifi cations herein are subject to change without prior notice.

MOUNTING AND OPERATION

GP3V…………………………………(when ℓ = 15 mm)

GP5V…………………………………(when ℓ = 15 mm)

Adjusting the number of revolution
These models are equipped with an electronic infi nice variable-speed drive and can change the number of revolutions according to use.
If you turn and set the dial scale (Fig. 6) to 6, the number of revolutions increases, and if you turn and set it to 1, the number of revolutions decreases.
Before use, set the number of revolutions using the dial. In so doing, refer to the following table as a rough guide.

NOTE
Use caution not to turn the dial scale to any value below 1 or above 6.
Caution when using near welding equipment
When using the grinder in the immediate vicinity of welding equipment, the rotational speed may become unstable. Do not use the grinder near welding equipment.
Precautions on the operation

1. Lightly press the wheel to the material to be ground. When grinding materials, a high-speed revolution is necessary. Use a hand grinder with high-speed revolution, minimizing the pressing force.
   CAUTION When using the tool at any value except the full speed (Dial scale 6), the motor cannot be suffi ciently cooled due to the decreased number of revolutions. This could result in the risk of burning and damaging the motor before an overload protective mechanism starts to function.
   Make sure that you use the tool by lightly applying it to the surface of the material when you use it at any value except full speed (Dial scale 6).

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

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- 0| m| V
Brass, bronze, aluminum| 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 shafts are prepared for grinding small surfaces. Their dimensions and shapes are shown in “Selecting accessories”.
Since the wheel shaft diameter is 3 mm, use the collet chuck for the 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 hazards.
3. Maintenance of the motor unit winding is the very “heart” of the power tool. Exercise due care to ensure the winding does not become damaged and/or wet with oil or water.
4. Inspecting the carbon brushes (Fig. 7) 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 ensure that they slide freely within the brush holders.
5. Replacing carbon brushes (Fig. 7)

〈Disassembly〉

1. Loosen the D4 tapping screw ⓒ retaining the tail cover ⓓ and remove the tail cover.
2. Use the auxiliary hexagonal wrench or small screwdriver to pull up the edge of the spring ⓔ that is holding down the carbon brush. Remove the edge of the spring toward the outside of the brush holder ⓕ.
3. Remove the end of the pig-tail ⓖ on the carbon brush ⓗ from the terminal section of the brush holder and then remove the carbon brush from the brush holder.

〈Assembly〉

1. Insert the end of the pigtail of the carbon brush in the terminal section of the brush holder.

2. Insert the carbon brush in the brush holder.

3. Use the auxiliary hexagonal wrench or small screwdriver to return the edge of the spring to the head of the carbon brush.
   NOTE Make sure the end of the spring is not holding the pigtail.

4. Mount the tail cover and tighten the D4 tapping screw.

CAUTION
In the operation and maintenance of power tools, the safety regulations and standards prescribed in each country must be observed.

GUARANTEE

We guarantee HiKOKI Power Tools in accordance with statutory/country specifi c regulations. This guarantee does not cover defects or damage due to misuse, abuse, or normal wear and tear. In case of a complaint, please send the Power Tool, undismantled, with the GUARANTEE CERTIFICATE found at the end of this Handling instruction, to a HiKOKI Authorized Service Center.
IMPORTANT
Correct connection of the plug The wires of the main lead are colored in accordance with the following code:
Blue: — Neutral
Brown: — Live
As the colors of the wires in the main lead of this tool may not correspond with the colored markings identifying the terminals in your plug proceed as follows: The wire colored blue must be connected to the terminal marked with the letter N or colored black. The wire colored brown must be connected to the terminal marked with the letter L or colored red. Neither core must be connected to the earth’s terminal.
NOTE: This requirement is provided according to BRITISH STANDARD 2769: 1984. Therefore, the letter code and color code may not be applicable to other markets except The United Kingdom.
Information concerning airborne noise and vibration
The measured values were determined according to
EN60745 and declared in accordance with ISO 4871. Measured A-weighted sound power level: 94 dB (A).
Measured A-weighted sound pressure level: 83 dB (A).
Uncertainty K: 3 dB (A).
Wear hearing protection.
Vibration total values (triax vector sum) determined according to EN60745.
Surface grinding:
Vibration emission value ah, SG = 4.0 m/s2
Uncertainty K = 1.5 m/s2
The declared vibration total value has been measured in accordance with a standard test method and may be used for comparing one tool with another. It may also be used in a preliminary assessment of exposure.
WARNING

• The vibration emission during actual use of the power tool can diff er from the declared total value depending on the ways in which the tool is used.
• Identify safety measures to protect the operator that is based on an estimation of exposure in the actual conditions of use (taking account of all parts of the operating cycle such as the times when the tool is switched off and when it is running idle in addition to the trigger time).

NOTE
Due to HiKOKI’s continuing program of research and development, the specifi cations herein are subject to change without prior notice.
EC DECLARATION OF CONFORMITY
We declare under our sole responsibility that Electronic Hand Grinder, identifi ed by type and specifi c identifi cation code 1), is in conformity with all relevant requirements of the directives 2) and standards 3). Technical fi le at 4) – See below.
The European Standard Manager at the representative offi ce in Europe is authorized to compile the technical fi le.
The declaration is applicable to the product affi xed CE marking.
1) GP3V C350642S
GP5V C350657S
2) 2006/42/EC, 2014/30/EU, 2011/65/EU
3) EN60745-1:2009+A11:2010
EN60745-2-3:2011+A2:2013+A11:2014+A12:2014+A13:2015
EN55014-1:2006+A1:2009+A2:2011
EN55014-2:1997+A1:2001+A2:2008
EN61000-3-2:2014
EN61000-3-3:2013
4) Representative offi ce in Europe
Hikoki Power Tools Deutschland GmbH
Siemensring 34, 47877 Willich, Germany
Head offi ce in Japan
Koki Holdings Co., Ltd.
Shinagawa Intercity Tower A, 15-1, Konan 2-chome,
Minato-ku, Tokyo, Japan
29. 6. 2018
Naoto Yamashiro
European Standard Manager

A. Nakagawa
Corporate Offi cer

806
Code No. C99706271 M
Printed in Malaysia

Documents / Resources

| HiKOKI GP 3V Direct Sander [pdf] Instruction Manual
GP 3V, GP 5V, GP 3V Direct Sander, GP 3V, Direct Sander, Sander
---|---

References

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