Metabo HPT Cordless Disc Grinder G 18DSL2 Instruction Manual

Metabo HPT Cordless Disc Grinder G 18DSL2 Instruction Manual

IMPORTANT SAFETY INSTRUCTIONS
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 in this Instruction Manual.
NEVER use this power tool in a manner that has not been specifically recommended by metabola 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 warnings 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 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 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, 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

• 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 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.

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.

6) 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.

SAFETY WARNINGS 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 or 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 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. Incorrectly sized accessories cannot be adequately guarded or controlled.

• f) Threaded 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. 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) Do not use a damaged accessory. Before each use inspect the accessory such as abrasive wheels for chips and cracks. If power tool or accessory is dropped, inspect for damage or install an undamaged accessory. After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart during this test time.

• h) Wear personal protective equipment. Depending on application, use face shield, safety goggles or safety glasses. As appropriate, wear dust mask, hearing protectors, gloves and workshop apron capable of stopping small abrasive or workpiece fragments.
  The eye protection must be capable of stopping flying debris generated by various operations. The dust mask or respirator must be capable of filtrating particles generated by your operation. Prolonged exposure to high intensity noise may cause hearing loss.

• i) Keep bystanders a safe distance away from work area. Anyone entering the work area must wear personal protective equipment. Fragments of workpiece or of a broken accessory may fly away and cause injury beyond immediate area of operation.

• j) Hold the power tool by insulated gripping surfaces only, when performing an operation where the cutting tool may contact hidden wiring. Contact with a “live” wire will also 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 the dust inside the housing and excessive accumulation of powdered metal may cause electrical hazards.

• o) Do not operate the power tool near 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 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 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 reactions or kickback forces, if proper precautions are taken.
• b) Never place your hand near the rotating accessory. Accessory may kickback over your hand.
• c) 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.
• 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 kickback and loss of control.

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 centre 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 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 worn down wheels from larger power tools. Wheel intended 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 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 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;
• ­ 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;
• ­ 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;
• ­ 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.
• ­ Do not allow foreign matter to enter the hole for connecting the rechargeable battery.
• ­ Never disassemble the rechargeable battery and charger.
• ­ Never short-circuit the rechargeable battery. Short-circuiting the battery will cause a great electric current and overheat. It results in burn or damage to the battery.
• ­ Do not dispose of the battery in fire. If the battery is burnt, it may explode.
• ­ Do not insert object into the air ventilation slots of the charger. Inserting metal objects or inflammables into the charger air ventilation slots will result in electrical shock hazard or damaged charger.
• ­ Bring the battery to the shop from which it was purchased as soon as the post-charging battery life becomes too short for practical use. Do not dispose of the exhausted battery.

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 apart and cause injury.

3. Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a “live” wire will make exposed metal parts of the tool “live” and shock the operator.

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

5. 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 page 12) may result in wheel breakage, flying wheel fragments, and resulting in death or serious injury.

6. NEVER touch moving parts. NEVER place your hands, fingers or other body parts near the tool’s moving parts.

7. 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.

8. 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.

9. 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.

10. 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.

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

12. 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.

13. Wheels and accessories must be securely mounted to the tool. Prevent potential injuries to yourself or others. Wheels and accessories which have been mounted to the tool should be secure and tight.

14. 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.

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 metabola HPT authorized service center.

16. NEVER leave tool running unattended. Turn power off. Don’t leave tool until it comes to a complete 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 18).

20. NEVER use the grinder in places where the sparks generated by the grinder 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 Z87.1.

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 15).

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 ceiling where you are going to operate here after.

28. Do not use the product if the tool or the battery terminals (battery mount) are deformed. Installing the battery could cause a short circuit that could result in smoke emission or ignition.

29. Keep the tool’s terminals (battery mount) free of swarf and dust.
    Prior to use, make sure that swarf and dust have not collected in the area of the terminals.
    During use, try to avoid swarf or dust on the tool from falling on the battery.
    When suspending operation or after use, do not leave the tool in an area where it may be exposed to falling swarf or dust. Doing so could cause a short circuit that could result in smoke emission or ignition.

30. Definitions for symbols used on this tool
    V ……….volts
    =- …….. direct current
    Hz …….. hertz
    A ………. amperes
    n ………. rated speed —/min.. revolutions or reciprocation per minute

IMPORTANT SAFETY INSTRUCTIONS FOR BATTERY CHARGER

WARNING
Death or serious bodily injury could result from improper or unsafe use of battery chargers. To avoid these risks, follow these basic safety instructions:

READ ALL INSTRUCTIONS

1. This manual contains important safety and operating instructions for battery charger Model UC18YKSL/ UC18YFSL.
2. Before using battery charger, read all instructions and cautionary markings on (1) battery charger, (2) battery, and (3) product using battery.
3. To reduce risk of injury, charge metabola HPT rechargeable battery type BSL18 series. Other type of batteries may burst causing personal injury and damage.
4. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons.
5. To reduce risk of damage to electric plug and cord, pull by plug when disconnecting battery charger.
6. Make sure cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress.
7. An extension cord should not be used unless absolutely necessary. Use of improper extension cord could result in a risk of fire and electric shock. If extension cord must be used make sure:
   a. That blades of extension cord are the same number, size, and shape as those of plug on battery charger:
   b. That extension cord is properly wired and in good electrical condition; and
   c. That wire size is large enough for AC ampere rating of battery charger as specified in Table 1.

• If the input rating of a battery charger is given in watts rather than in amperes, the corresponding ampere rating is to be determined by dividing the wattage rating by the voltage rating for example:

  8. Do not operate the battery charger with a damaged cord or plug. If either is damaged, replace immediately.
  9. Do not operate battery charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman.
  10. Do not disassemble battery charger; take it to a qualified serviceman when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.
  11. To reduce risk of electric shock, unplug charger from receptacle before attempting any maintenance or cleaning. Removing the battery will not reduce this risk.

IMPORTANT SAFETY INSTRUCTIONS FOR USE OF THE BATTERY AND BATTERY CHARGER
You must charge the battery before you can use the power tool. Before using the model UC18YKSL battery charger, be sure to read all instructions and cautionary statements on it, the battery and in this manual.

CAUTION
USE ONLY metabola HPT BATTERY TYPES BSL18 SERIES. OTHER TYPES OF BATTERIES MAY BURST AND CAUSE INJURY!

Follow these instructions to avoid the risk of injury:

WARNING: Improper use of the battery or battery charger can lead to serious injury. To avoid these injuries:

1. NEVER disassemble the battery.
2. NEVER incinerate the battery, even if it is damaged or is completely worn out. The battery can explode in a fi re.
3. NEVER short-circuit the battery.
4. NEVER insert any objects into the battery charger’s air vents. Electric shock or damage to the battery charger may result.
5. EVER charge outdoors. Keep the battery away from direct sunlight and use only where there is low humidity and good ventilation.
6. NEVER charge when the temperature is below 32°F (0°C) or above 104°F (40°C).
7. NEVER connect two battery chargers together.
8. NEVER insert foreign objects into the hole for the battery or the battery charger.
9. NEVER use a booster transformer when charging.
10. NEVER use an engine generator or DC power to charge.
11. NEVER store the battery or battery charger in places where the temperature may reach or exceed 104°F (40°C) such as inside metal box or car.
12. NEVER expose the battery or battery charger to rain or wet conditions.
13. ALWAYS operate charger on standard household electrical power (120 volts). Using the charger on any other voltage may overheat and damage the charger.
14. ALWAYS wait at least 15 minutes between charges to avoid overheating the charger.
15. ALWAYS disconnect the power cord from its receptacle when the charger is not in use.

CAUTION ON LITHIUM-ION BATTERY
To extend the lifetime, the lithium-ion battery equips with the protection function to stop the output. In the cases of 1 to 3 described below, when using this product, even if you are pulling the switch, the motor may stop. This is not the trouble but the result of protection function.

1. When the battery power remaining runs out, the motor stops. In such case, charge it up immediately.
2. If the tool is overloaded, the motor may stop. In this case, release the switch of tool and eliminate causes of overloading. After that, you can use it again.
3. If the battery is overheated under overload work, the battery power may stop. In this case, stop using the battery and let the battery cool. After that, you can use it again.

Furthermore, please heed the following warning and caution.

WARNING
In order to prevent any battery leakage, heat generation, smoke emission, explosion and ignition beforehand, please be sure to heed the following precautions.

1. Make sure that swarf and dust do not collect on the battery.
   During work make sure that swarf and dust do not fall on the battery. Make sure that any swarf and dust falling on the power tool during work do not collect on the battery.
   Do not store an unused battery in a location exposed to swarf and dust. Before storing a battery, remove any swarf and dust that may adhere to it and do not store it together with metal parts (screws, nails, etc.).

2. Do not pierce battery with a sharp object such as a nail, strike with a hammer, step on, throw or subject the battery to severe physical shock.

3. Do not use an apparently damaged or deformed battery.

4. Do not use the battery in reverse polarity.

5. Do not connect directly to an electrical outlets or car cigarette lighter sockets.

6. Do not use the battery for a purpose other than those specified.

7. If the battery charging fails to complete even when a specified recharging time has elapsed, immediately stop further recharging.

8. Do not put or subject the battery to high temperatures or high pressure such as into a microwave oven, dryer, or high pressure container.

9. Keep away from fire immediately when leakage or foul door are detected.

10. Do not use in a location where strong static electricity generates.

11. If there is battery leakage, foul odor, heat generated, discoloured or deformed, or in any way appears abnormal during use, recharging or storage, immediately remove it from the equipment or battery charger, and stop use.

12. Do not immerse the battery or allow any fluids to flow inside. Conductive liquid ingress, such as water, can cause damage resulting in fire or explosion. Store your battery in a cool, dry place, away from combustible and flammable items. Corrosive gas atmospheres must be avoided.

CAUTION

1. If liquid leaking from the battery gets into your eyes, do not rub your eyes and wash them well with fresh clean water such as tap water and contact a doctor immediately. If left untreated, the liquid may cause eye-problems.
2. If liquid leaks onto your skin or clothes, wash well with clean water such as tap water immediately. There is a possibility that this can cause skin irritation.
3. If you find rust, foul odor, overheating, discolour, deformation, and/or other irregularities when using the battery for the first time, do not use and return it to your supplier or vendor.

WARNING
If an electrically conductive foreign object enters the terminals of the lithium ion battery, a short-circuit may occur resulting in the risk of fire. Please observe the following matters when storing the battery.
Do not place electrically conductive cuttings, nails, steel wire, copper wire or other wire in the storage case.
Either install the battery in the power tool or store by securely pressing into the battery cover until the ventilation holes are concealed to prevent short-circuits (See Fig. 3).

REGARDING LITHIUM-ION BATTERY TRANSPORTATION
When transporting a lithium-ion battery, please observe the following precautions.

WARNING
Notify the transporting company that a package contains a lithium-ion battery, inform the company of its power output and follow the instructions of the transportation company when arranging transport.
Lithium-ion batteries that exceed a power output of 100 Wh are considered to be in the freight classification of Dangerous Goods and will require special application procedures.
For transportation abroad, you must comply with international law and the rules and regulations of the destination country.

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

1. Cordless Disc Grinder (G18DSL2)

SPECIFICATIONS

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.
• Grinding of synthetic resins, slate, brick, marble.

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

REMOVAL AND INSTALLATION METHOD OF BATTERY

1. Battery removal Hold the handle tightly and push the battery latch to remove the battery (see Fig. 5).
   CAUTION Never short-circuit the battery.

2. Battery installation Insert the battery while observing its polarities (see Fig. 5).

CHARGING METHOD

NOTE
Before plugging into the receptacle, make sure the following points.

• The power source voltage is stated on the nameplate.
• The cord is not damaged.

WARNING
Do not charge at voltage higher than indicated on the nameplate. If charged at voltage higher than indicated on the nameplate, the charger will burn up.

1. Connect the charger’s power cord to a receptacle. When the power cord is connected, the charger’s pilot lamp will blink in red. (At 1-second intervals)
   
   

2. Insert the battery to the battery charger. Insert the battery into the battery charger as shown in Fig. 6

3. Charging When the battery is connected to the battery charger, charging will commence and the pilot lamp will light in red. (See Table 2)

NOTE
If the pilot lamp flakers in red, pull out the plug from the receptacle and check if the battery is properly mounted. When the battery is fully charged, the pilot lamp will blink in red slowly. (At 1-second intervals) (See Table 2)

(1) Pilot lamp indication The indications of the pilot lamp will be as shown in Table 2, according to the condition of the charger or the rechargeable battery.

(2) Regarding the temperature of the rechargeable battery. The temperatures for rechargeable batteries are as shown in the Table 3, and batteries that have become hot should be cooled for a while before being recharged.

(3) Regarding recharging time (At 68°F (20°C))

NOTE
The charging time may vary according to temperature and power source voltage.

4. Disconnect battery charger from the receptacle.

CAUTION
Do not pull the plug out of the receptacle by pulling on the cord. Make sure to grasp the plug when removing from receptacle to avoid damaging cord.

5. Remove the battery from the battery charger. Supporting the battery charger with hand, pull out the battery from the battery charger.
Regarding electric discharge in case of new batteries, etc.
As the internal chemical substance of new batteries and batteries that have not been used for an extended period is not activated, the electric discharge might be low when using them the first and second time. This is a temporary phenomenon, and normal time required for recharging will be restored by recharging the batteries 2­3 times.
How to make the batteries perform longer.
(1) Recharge the batteries before they become completely exhausted. When you feel that the power of the tool becomes weaker, stop using the tool and recharge its battery. If you continue to use the tool and exhaust the electric current, the battery may be damaged and its life will become shorter.
(2) Avoid recharging at high temperatures. A rechargeable battery will be hot immediately after use. If such a battery is recharged immediately after use, its internal chemical substance will deteriorate, and the battery life will be shortened. Leave the battery and recharge it after it has cooled for a while.

CAUTION

• When the battery charger has been continuously used, the battery charger will be heated, thus constituting the cause of the failures. Once the charging has been completed, give 15 minutes rest until the next charging.
• If the battery is charged while it is heated because it has been left for a long time in a location subject to direct sunlight or because the battery has just been used, the pilot lamp of the charger lights for 1 second, does not light for 0.5 seconds (off for 0.5 seconds). The battery will not be recharged. In such a case, let the battery cool before charging.
• When the pilot lamp flickers (at 0.2-second intervals), check for and take out any foreign objects in the charger’s battery connector. If there are no foreign objects, it is probable that the battery or charger is malfunctioning. Take it to your authorized Service Center.

PRIOR TO OPERATION

1. Power switch Ensure that the switch is in the OFF position.

2. Check your work environment Ensure the following before operation:
   No flammable 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.

3. 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. [How to attach and adjust the wheel guard] (Fig. 7)
   Slightly loosen the screw on the wheel guard.
   Install the wheel guard to the packing gland, turn 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.

4. 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 17 of this manual for Depressed Center Wheel Assembly and Disassembly.

5. Test the 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 eye protection. Turn the grinder “on”, and make sure the grinder runs smoothly and shows no abnormalities. Duration of the trial run is as follows:
   When depressed center wheel
   is replaced … 3 minutes or more
   When starting daily work …. 1 minute or more

6. Use only properly rated depressed center 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.

7. Check the push button. Make sure that the push button is disengaged by pushing push button two or three times before turning on the grinder. (Fig. 11)

8. About Remaining Battery Indicator When pressing the remaining battery indicator switch, the remaining battery indicator lamp lights and the battery remaining power can be checked. (Fig. 8) When releasing your finger from the remaining battery indicator switch, the remaining battery indicator lamp goes off. The table 5 shows the state of remaining battery indicator lamp and the battery remaining power.

As the remaining battery indicator shows somewhat differently depending on ambient temperature and battery characteristics, read it as a reference.

NOTE

• When using a Multi-volt battery, please refer to the indicator lamp on the battery for the battery remaining power.
• Do not give a strong shock to the switch panel or break it. It may lead to a trouble.
• To save the battery power consumption, the remaining battery indicator lamp lights while pressing the remaining battery indicator switch.

GRINDER OPERATION

CAUTION
To extend the lifetime, the lithium-ion battery equips with the protection function to stop the output. Therefore, if the tool is overloaded, the motor may stop. However, this is not the trouble but the result of protection function. In this case, release the switch of tool and eliminate the causes of overloading.

NOTE
To prevent injuries, this product has a function that prevents unexpected motor rotation when the battery is inserted. The motor will not run if the battery is inserted while the switch is still on. After installing the battery, turn the switch off and then back on again.
The G18DSL2 model is equipped with a protection function that will shut down the tool in the event of an overload. When the overload protection feature has been activated, the motor may stop. In this case, release the tool switch and eliminate causes of overloading. After that you can use it again.

1. Hold the grinder firmly by its housing and side handle (Fig. 2). The grinder produces a counterforce which must be controlled by firmly holding onto the grinder.
2. Turn the grinder “ON” (Fig. 9) While holding the grinder firmly, slide the switch to the “ON” position with one finger to turn on the tool. Releasing the switch will turn off the tool. For continued operation, slide the switch to the “ON” position and press down the “ON” position of the switch to lock it in place. Turn the grinder “OFF” (Fig. 9) Press the “OFF” position of the switch to release the lock and turn the grinder off.

3. 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
   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.

4. Use proper grinding angle. Grind only with the wheel’s edge by lifting the grinder 15° to 30°, as shown in Fig. 10.
   CAUTION Do not use the entire surface of the depressed center wheel. Use only the edge of the depressed center wheel.

5. Move the grinder in the proper direction. When using a new depressed center wheel in direction A (Fig. 10), the wheel edge may cut into the workpiece. In this case, grind in direction B (Fig. 10). Once the wheel edge is worn, the workpiece can be ground in both directions.

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 no lay the grinder down in areas of dust or dirt until it has come to a complete stop.

DEPRESSED CENTER WHEEL ASSEMBLY AND DISASSEMBLY

WARNING
Be sure to turned off the switch and pull out the battery.

1. Assembly
   (1) Turn the disc grinder upside-down so that the spindle is facing upward.
   (2) Align the oval-shaped indentation of the wheel washer with the notched part of the spindle, then attach them.
   (3) Fit the protuberance of the depressed center wheel onto the wheel washer.
   (4) Screw the wheel nut onto the spindle.
   (5) While pushing the push button with one hand, lock the spindle by turning the depressed center wheel slowly with the other hand. Tighten the wheel nut by using the supplied wrench as shown in Fig. 11.

CAUTION Tighten the wheel nut securely and confirm that the depressed center wheel does not wobble.

2. Disassembly To remove the depressed center wheel, simply reverse the above-mentioned procedure.

MAINTENANCE AND INSPECTION

WARNING:

Be sure to turned off the switch and pull out the battery. 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 worn 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 or a transformation in the wheel, replace it immediately.

2. Check the Screws Loose screws are dangerous. Regularly inspect them and make sure they are tight.
   CAUTION Using this power tool with loosened screws is extremely dangerous.

3. Maintenance of the motor 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. 12) The motor employs carbon brushes which are consumable parts. Since and excessively worn carbon brush can result in motor trouble, replace the carbon brush with new ones 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.

NOTE When replacing the carbon brush with a new one, be sure to use the metabola HPT Carbon Brush Code No. 999101.

5. Replacing carbon brushes Take out the carbon brush by first removing the brush cap and then hooking the protrusion of the carbon brush with a flat head screw driver, etc., as shown in Fig. 13.
   When installing the carbon brush, choose the direction so that the nail of the carbon brush agrees with the contact portion outside the brush tube. Then push it in with a finger as illustrated in Fig. 14 Lastly, install the brush cap.

CAUTION
Be absolutely sure to insert the nail of the carbon brush into the contact portion outside the brush tube. (You can insert whichever one of the two nails provided.)
Caution must be exercised since any error in this operation can result in the deformed nail of the carbon brush and may cause motor trouble at an early stage.

6. Check for Dust Dust may be removed with a soft cloth or a cloth dampened with soapy water. Do not use bleach, chlorine, gasoline or thinner, for they may damage the plastics.

7. Inspection of terminals (tool and battery) Check to make sure that swarf and dust have not collected on the terminals. On occasion check prior, during and after operation.
   CAUTION Remove any swarf or dust which may have collected on the terminals. Failure to do so may result in malfunction.

8. Cleaning the filter After use, remove any grime or dust from the filter with an airgun or other tool.

9. Disposal of the exhausted battery
   WARNING
   Do not dispose of the exhausted battery. The battery must explode if it is incinerated. The product that you have purchased contains a rechargeable battery. The battery is recyclable. At the end of it’s useful life, under various state and local laws, it may be illegal to dispose of this battery into the municipal waste stream. Check with your local solid waste officials for details in your area for recycling options or proper disposal.

10. Storage Storing in a place below 104°F (40°C) and out of the reach of children.
    NOTE Storing lithium-ion batteries Make sure the lithium-ion batteries have been fully charged before storing them. Prolonged storage (3 months or more) of batteries with a low charge may result in performance deterioration, significantly reducing battery usage time or rendering the batteries incapable of holding a charge. However, significantly reduced battery usage time may be recovered by repeatedly charging and using the batteries two to five times. If the battery usage time is extremely short despite repeated charging and use, consider the batteries dead and purchase new batteries.

11. Service and repairs
    All quality power tools will eventually require servicing 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 be performed by a metabola HPT AUTHORIZED SERVICE CENTER, ONLY.

CAUTION
In the operation and maintenance of power tools, the safety regulations and standards prescribed in each country must be observed.
Important notice on the batteries for the metabola HPT cordless power tools Please always use one of our designated genuine batteries. We cannot guarantee the safety and performance of our cordless power tool when used with batteries other than these designated by us, or when the battery is disassembled and modified (such as disassembly and replacement of cells or other internal parts).

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.

NOTE Accessories are subject to change without any obligation on the part of the metabola HPT.

STANDARD ACCESSORIES

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

WARNING:

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of Califia 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 form chemically-treated lumber.

Your risk form 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 these dust masks that are specially designed to fitter out microscopic particles

Please contact Koki Holdings America Ltd. at 1-800-59-TOOLS (Toll Free), or metabola HPT AUTHORIZED POWER TOOL SERVICE CENTER regarding COLLECTION.

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 Ameriaca Ltd. Canadian Branch
3405 American Drive, Units 9-10,
Mississauga, ON, L4V 1T6

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