909 AG125 User manual

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Code: AG125
Date: 110301 Edition: 06 Op: DCR
INSTRUCTION MANUAL
AG125
10 50 W
125mm ( 5" )
SL IM RE A R H A NDL E
A N G L E GRINDER

2
CONTENTS
Warranty Power Tools
For full details please visit us at www.909.com
Warranty 2
Introduction 3
Environmental protection 3
Description of symbols 3
Specifications 3
General safety rules 4
Additional safety rules for angle grinders 5
Safety instructions for all operations 6
Further safety instructions for all operations 7
Additional safety instructions for grinding
and cutting-off operations 8
Additional safety instructions for cutting-off operations 8
Contents of carton 9
Unpacking 9
Know your product 10
Disc assembly showing flange requirements 10
Setting up 11
Operation 11
Switching on and off 11
Replacing a disc 12
Lubrication 13
Power cord maintenance 13
Cleaning 13
General inspection 13

3
Description of symbols
The rating plate on your tool may show symbols. These
represent important information about the product or
instructions on its use.
Wear hearing protection.
Wear eye protection.
Wear breathing protection.
Double insulated for additional protection.
Conforms to relevant standards for
electromagnetic compatibility.
For safe operation read instruction manual.
Specifications
Nominal voltage: 230–240 Vac ~ 50Hz
Input power: 1050 W
No-load speed: 11,000 min-1
Insulation class: Double insulated
Disc size: 125 mm
Spindle: M14
Disc bore diameter: 22.2 mm
Sound pressure level: 95 dB(A)
Weight: 2.7 kg
Introduction
Your new 909 power tool will more than satisfy
your expectations. It has been manufactured under
stringent 909 Quality Standards to meet superior
performance criteria.
You will find your new tool easy and safe to operate,
and, with proper care, it will give you many years
of dependable service.
CAUTION. Carefully read through this entire Instruction
Manual before using your new 909 Power Tool. Take
special care to heed the Cautions and Warnings.
Your 909 power tool has many features that will make
your job faster and easier. Safety, performance, and
dependability have been given top priority in the
development of this tool, making it easy to maintain
and operate.
Environmental protection
Recycle unwanted materials instead
of disposing of them as waste. All tools,
hoses and packaging should be sorted,
taken to the local recycling centre and
disposed of in an environmentally safe way.

4
General safety rules
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) To reduce the risk of electric shock, the manufacturer
recommends the use of a residual current device
with a rated residual current of 30mA or less at
all times.
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.

5
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.
h) This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person
responsible for their safety.
i) Children should be supervised to ensure that they do
not play with the appliance.
5) Service
a) Have your power tool serviced by a qualified repair
person using only identical replacement parts. This
will ensure that the safety of the power tool is maintained.
Additional safety rules for angle grinders
• Fully unwind cable drum extension leads to avoid potential
overheating.
• When an extension cable is required, you must ensure
that it has the right ampere rating for your power tool and
is in safe electrical condition.
• Always switch it off before you put the angle grinder down.
• Do not let anyone under 18 years operate this tool.
• Rags, cloths, cord, string and the like should never be left
around the work area.
• If you are interrupted when operating the tool, complete
the process and switch off before looking up.
• Periodically check that all nuts, bolts and other fixings are
properly tightened.
• Check the disc before mounting it into the angle grinder.
Check by striking it with a wooden handle whilst balancing
the disc on your finger. Listen for a ring and do not use if
the sound is dull, as the disc may be cracked.
• When the disc is installed, run it for at least one minute to
ensure that it does not have a fault. It is always advisable
to stay out of the line of the disc rotation when testing or
when using the tool.
• Do not use a disc marked with a lower RPM than that of
the no load speed shown on the rating plate.
• Use discs only of the prescribed diameter.
• Do not use the angle grinder for buffing or polishing under
any circumstances.

6
• Never try to operate the angle grinder without the guard
in place.
• Do not secure the angle grinder in a vice or work bench
and use it as a static grinder. It can lead to serious injury.
• Never apply excessive pressure to the disc. It might
shatter causing personal injury.
• Ensure the work piece to be ground or cut, is held tight in
a vice or other clamping system.
• Always use the front handle and ensure a good grip on the
grinder housing with one hand and the front handle with
the other hand before proceeding with any work.
• Make sure that the disc is not in contact with the work
when you start the grinder.
• Be careful not to damage the spindle or either of the
disc flanges. Damage to these parts could result in disc
breakage.
• Do not press the spindle lock button whilst the spindle
is turning.
• Only use good quality grinding and cut off discs. Cheap
poor quality discs tend to glaze up which loads the motor
and can damage it. Use discs for their designated purpose
only. For instance, do not use cutting discs for grinding or
metal wheels on masonry.
• Watch out for flying sparks. Hold the tool at an angle of
approximately 15º to 30º to the work piece surface.
• Let the disc do the grinding or cutting at a reasonable
feed, as overloading will occur if too much pressure is
applied and the disc slows resulting in inefficient cutting
and possible damage to the motor.
• When using the grinder, use safety equipment including
safety goggles or shield, ear protection, dust mask and
protective clothing including safety gloves.
ALWAYS WEAR EYE PROTECTION
Wear goggles
Wear hearing protection
Wear a breathing mask
Safety instructions for all operations
Safety warnings common for grinding,
abrasive cutting-off operations:
a) This power tool is intended to function as a grinder,
or cut-off tool. 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.
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) The arbour size of wheels, flanges, backing pads or
any other accessory must properly fit the spindle of
the power tool. Accessories with arbour holes 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, backing pad for cracks, tear or
excess wear, wire brush for loose or cracked wires.
If power tool or accessory is dropped, inspect for
damage or install an undamaged accessory. After
inspecting and installing an accessory, position
yourself and bystanders away from the plane of
the rotating accessory and run the power tool at
maximum no-load speed for one minute. Damaged
accessories will normally break apart during this test time.

7
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 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 shock the
operator.
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.
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 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.

8
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.
Additional safety instructions for grinding
and cutting-off operations
Safety warnings specific for grinding and
abrasive cutting-off 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 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 and accidental contact with wheel.
c) 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.
d) 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.
e) 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.
Additional safety instructions
for cutting-off operations
Additional safety warnings specific for
abrasive cutting-off operations:
a) Do not “jam” the cut-off wheel or apply excessive
pressure. Do not attempt to make an excessive depth
of cut. Overstressing the wheel increases the loading and
susceptibility to twisting or binding of the wheel in the cut
and the possibility of kickback or wheel breakage.
b) Do not position your body in line with and behind
the rotating wheel. When the wheel, at the point of
operation, is moving away from your body, the possible
kickback may propel the spinning wheel and the power
tool directly at you.
c) When wheel is binding or when interrupting a cut
for any reason, switch off the power tool and hold
the power tool motionless until the wheel comes to
a complete stop. Never attempt to remove the cut-
off wheel from the cut while the wheel is in motion
otherwise kickback may occur. Investigate and take
corrective action to eliminate the cause of wheel binding.
d) Do not restart the cutting operation in the workpiece.
Let the wheel reach full speed and carefully re-enter
the cut. The wheel may bind, walk up or kickback if the
power tool is restarted in the workpiece.
e) Support panels or any oversized workpiece to
minimize the risk of wheel pinching and kickback.
Large workpieces tend to sag under their own weight.
Supports must be placed under the workpiece near the
line of cut and near the edge of the workpiece on both
sides of the wheel.
f) Use extra caution when making a “pocket cut” into
existing walls or other blind areas. The protruding
wheel may cut gas or water pipes, electrical wiring or
objects that can cause kickback.
WARNING. We recommend the use of a residual current
device with a residual current rating of 30mA or less.

9
Contents of carton
The 909 AG125 angle grinder is supplied with the following
accessories as standard:
• Pin wrench
• Side handle
• 125mm metal grinding disc
• Instruction manual
Unpacking
Due to modern mass production techniques, it is unlikely that
your 909 power tool is faulty or that a part is missing. If you
find anything wrong, do not operate the tool until the parts
have been replaced or the fault has been rectified. Failure to
do so could result in serious personal injury.

10
Know your product
Before using the angle grinder, familiarise yourself with all
the operating features and safety requirements.
Use the tool and accessories only for the applications
intended. All other applications are expressly ruled out.
Depressed disc (thicker than 4mm) Depressed disc (4mm or less in thickness)
Raised inner
part facing
the disc
Raised inner
part facing
away from
the disc
Disc assembly showing flange requirements
11
10
11
10
9
9
8 8
1. On/off switch
2. Power lock OFF/ON button
3. Spindle lock button
4. Disc guard
5. Front handle
6. Mounting points for
the handle
7. Motor housing
8. Pin wrench
9. Outer flange
10. Disc
11. Inner flange
12. Quick release guard lever
1
76
3
12
4
5
2

11
Setting up
Multi-position front handle
Screw the front handle (5) into
the most suitable mounting port
(6) (top, left side or right side) to
suit the application. Ensure that
the handle is fully screwed in
place and firm.
Disc guard
WARNING. Switch off the grinder and disconnect it from the
power point.
NOTE. Grinding operations normally require the angle
grinder to be held with the grinding disc parallel to the
plane of the workpiece whilst cutting operations normally
require the angle grinder to be held with the cutting disc at
right angles to the workpiece. Take the time to find the best
combination of front handle and slimline handle positions to
suit the task at hand. It can make a considerable difference
to the levels of convenience and safety of operation.
1. Open the quick release guard lever (12).
2. Position the lug on the inside of the central guard ring in
the vertical slot in the spindle cover and press the guard
onto the spindle cover.
3. Twist the guard to the appropriate position for either
grinding or cutting.
4. Lock the guard in position with the quick release guard
lever.
Operation
This angle grinder can be used for grinding and cutting steel,
stone or ceramic workpieces such as pipe, box section,
rectangular, angle iron steel bar, house bricks and tiles. Do
not attempt to grind wood or a soft metal such as lead. The
material will quickly “fill” the disc and render it useless.
Before starting the grinder first ensure that the disc, disc
guard and tool are in good condition.
Position the guard (4) as described in the disc guard section
so that it will deflect hot sparks away from the operator.
Switching on and off
1. Plug the power cord into the
power point.
2. Start the tool by depressing
the lock OFF / ON button (2)
and pull trigger switch (1).
Release the trigger to stop the
tool.
3. If you press the lock OFF/
ON button (2) while the trigger
switch is depressed, the
switch is kept in the operating
position. To release the lock on
button, press and release the
trigger switch.
4. Hold the grinder firmly while
it is switched on and only
apply gentle pressure to the
workpiece. Little more than
the weight of the tool should
be applied to give the best
and most efficient material
removal. Forcing and excessive
pressure can cause dangerous
disc fracture or damage to
the tool. Hold the grinder at
approximately 15° to 30º to the work and move slowly.
15º
30º

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5. Once the grinding or cutting is finished, pull in and
release the on/off switch (1) to stop the grinder.
WARNING. Avoid flying sparks and ensure they do not hit
any inflammable materials, as they are very hot and could
cause personal injury or a fire.
WARNING. The disc continues to turn for a few seconds
even though the switch is turned off. Keep your hands well
away from the moving disc.
Replacing a disc
CAUTION. Switch off the grinder and disconnect it from the
power point.
1. Turn the angle grinder on to its back and press the
spindle lock button (3) and rotate the spindle until it locks.
2. Insert the pins of the wrench (8) into the holes in the
outer flange (9) and remove it and the old disc.
Note. Do not remove the inner flange (11).
WARNING. Do not use a disc marked with a lower RPM than
that of the Max. no-load speed shown on the rating plate.
3. Clean the flanges and check the new disc.
4. Holding the angle grinder with
the spindle facing upwards,
check that the inner flange is
on the spindle and correctly
located. The two machined
flat sections must face the
angle grinder and locate in the
appropriate position on the
spindle.
5. Place the disc onto the spindle with the label facing the
angle grinder. The hole in the disc should locate onto the
spindle and fit firmly into the spigot section of the inner
flange.
Note. Depending on whether the disc has a flat inner
section or a depressed inner section, proceed as follows.
6. For discs with a flat inner section, screw on the outer
flange (9) with the protruding spigot section facing away
from the disc.
7. For discs with a depressed inner section, screw on the
outer flange with the protruding spigot section facing the
disc so that it locates in the hole in the disc.
8. Hand tighten the outer flange
until the disc is secure.
9. Press the spindle lock button
and tighten the flange with the
pin wrench.
10. Turn the new disc by hand,
ensuring that it is tightly
secured and that it rotates
fully and does not wobble unduly.

13
11. Run the angle grinder under no load for at least one
minute to ensure the new disc is in good condition.
Make sure you are wearing all the safety gear and that
you face the grinder away from you.
CAUTION. Do not use excessive force to clamp the disc.
It could crack it and cause failure during use.
WARNING. Do not immerse the disc into any type of
lubricant including water. This angle grinder is designed as a
dry grinder/cutter. Failure to observe this warning could result
in a fatal shock.
Lubrication
The grease in the gearbox will require replacement after
extensive use of the tool. Please go to a qualified service
agent to perform this service.
Power cord maintenance
If the supply cord needs replacing, the task must be carried
out by the manufacturer, the manufacturer’s agent, or an
authorised service centre in order to avoid a safety hazard.
Cleaning
1. Keep the tool’s air vents unclogged and clean at all times.
2. Remove dust and dirt regularly. Cleaning is best done with
a rag. Wear safety goggles or an eye shield and gloves
whist cleaning.
3. Re-lubricate all moving parts at regular intervals.
4. Never use caustic agents to clean plastic parts.
CAUTION. Do not use cleaning agents to clean the plastic
parts of the tool. A mild detergent on a damp cloth is
recommended. Water must never come into contact with
the tool.
General inspection
Regularly check that all the fixing screws are tight,
particularly the outer flange. They may vibrate loose
over time.