Atlas Copco G2422-1 Instruction sheet

G2422-1
Printed Matter No. 9839 0485 01 Die grinder
Valid from Serial No. A6720001
Valid to Serial No. A9810001
2017-11-25
Product Instructions
G2422-1
(20000 r/min)
(20000 rpm)
8423031247
WARNING
Read all safety warnings and instructions
Failure to follow the safety warnings and instructions may result in
electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference

EN G2422-1
2© Atlas Copco Industrial Technique AB - 9839 0485 01

3
© Atlas Copco Industrial Technique AB - 9839 0485 01
Table of Contents
Product information..................................................................... 5
General information................................................................. 5
Safety signal words........................................................ 5
Warranty ........................................................................ 5
ServAid .......................................................................... 6
Website .......................................................................... 6
Safety Data Sheets MSDS/SDS .................................... 6
Country of origin............................................................. 6
Dimensional drawings.................................................... 6
Overview ................................................................................. 6
Design and function ....................................................... 6
Technical data................................................................ 7
Service overview ..................................................................... 7
Maintenance and service instructions............................ 7
Replacement of vanes ................................................... 7
Service recommendations ............................................. 8
Installation .................................................................................... 9
Installation requirements ......................................................... 9
Air quality ....................................................................... 9
Air lubrication guide ....................................................... 9
Compressed air connection ........................................... 9
Installation instructions............................................................ 9
Installation of vibrating tools........................................... 9
Operation .................................................................................... 10
Ergonomic guidelines............................................................ 10
Setting-up instructions........................................................... 11
Operating instructions ........................................................... 11
Visual inspection .......................................................... 11
Operation instructions .................................................. 12
Mounted wheel and carbide burr ................................. 12
Service ........................................................................................ 14
Maintenance instructions....................................................... 14
Maintenance and service instructions.......................... 14
Service recommendations ........................................... 14
Replacement of vanes ................................................. 14
Lubrication instructions.......................................................... 14
Rust protection and cleaning ....................................... 14
Lubrication ................................................................... 15

4© Atlas Copco Industrial Technique AB - 9839 0485 01
Lubricating guide.......................................................... 15
Dismantling/Assembling instructions..................................... 15
Instructions for vane motor .......................................... 15
Testing................................................................................... 17
Recycling .................................................................................... 18
Recycling instruction ............................................................. 18

G2422-1 EN Product information
© Atlas Copco Industrial Technique AB - 9839 0485 01 5
Product information
General information
WARNING Risk of Property Damage or Severe Injury
Ensure that you read, understand and follow all instructions before operating
the tool. Failure to follow all the instructions may result in electric shock,
fire, property damage and/or severe bodily injury.
►Read all safety Information delivered together with the different parts of
the system.
►Read all product Instructions for installation, operation and maintenance
of the different parts of the system.
►Read all locally legislated safety regulations with regard to the system
and parts thereof.
►Save all safety information and instructions for future reference.
Safety signal words
The safety signal words Danger, Warning, Caution, and Notice have the follow-
ing meanings:
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if
not avoided, could result in minor or moderate injury.
NOTICE NOTICE is used to address practices not related to personal injury.
Warranty
• Product warranty will expire 12 months after the product is first taken into
use, but will in any case expire at the latest 13 months after delivery.
• Normal wear and tear on parts is not included within the warranty.
• Normal wear and tear is that which requires a part change or other ad-
justment/overhaul during standard tools maintenance typical for that pe-
riod (expressed in time, operation hours or otherwise).
• The product warranty relies on the correct use, maintenance, and repair of
the tool and its component parts.
• Damage to parts that occurs as a result of inadequate maintenance or per-
formed by parties other than Atlas Copco or their Certified Service Partners
during the warranty period is not covered by the warranty.
• To avoid damage or destruction of tool parts, service the tool according to
the recommended maintenance schedules and follow the correct instruc-
tions.
• Warranty repairs are only performed in Atlas Copco workshops or by Certi-
fied Service Partners.
Atlas Copco offers extended warranty and state of the art preventive mainte-
nance through its ToolCover contracts. For further information contact your lo-
cal Service representative.

Product information EN G2422-1
6© Atlas Copco Industrial Technique AB - 9839 0485 01
For electrical motors:
• Warranty will only apply when the electric motor has not been opened.
ServAid
ServAid is a portal that contains the most up-to-date product information such
as:
- Safety Information
- Installation, Operation and Service Instructions
- Exploded views
It is also possible to order spare parts, service tools and accessories for the
product of your choice directly from ServAid. It is continuously updated with
information about new and redesigned products.
If translations exist, you can view content in the language of your choice. Ser-
vAid offers advanced search functionality of our entire product range and can
also be used to display information about obsolete products.
ServAid is available on DVD and on the website:
https://servaid.atlascopco.com
For further information contact your Atlas Copco sales representative or e-mail
us at:
[email protected]
Website
Log in to Atlas Copco: www.atlascopco.com.
You can find information concerning our products, accessories, spare parts and
published matters on our website.
Safety Data Sheets MSDS/SDS
The safety data sheets describes chemical products sold by Atlas Copco.
For more information, consult the website:
www.atlascopco.com
Choose Products - Safety Data Sheets, and follow the instructions on the
page.
Country of origin
Please refer to the information on the product label.
Dimensional drawings
For information about the dimensions of a product, see the Dimensional draw-
ings archive:
http://webbox.atlascopco.com/webbox/dimdrw
Overview
Design and function
This die grinder is intended for mounted wheels and rotary burrs only. This
model is lubricated. The machine, its attachments and accessories must only be
used for the purpose for which they were designated, all other use is prohibited.

G2422-1 EN Product information
© Atlas Copco Industrial Technique AB - 9839 0485 01 7
• Never use grinding wheels attached with an adapter as this machine is not
fitted with a wheel guard
• Never attach circular saw blades or other cutters than the abrasive wheels or
brushes specified for the tool
Technical data
Ordering No 8423031247
Model G2422-1
Max wheel diameter - mm (- in)
Max pad diameter - mm (- in)
Spindle thread -
Spindle length - mm (- in)
Air inlet thread 1/41/4 in
Air consumption at free speed 10.3 l/s (21.8 cfm)
Air consumption at max output 13.0 l/s (27.5 cfm)
Max working pressure 7 bar (102 psig)
Max free speed 20000 r/min (20000 rpm)
Max output 0.35 kW (0.47 hp)
Motor type Vane
Recommended hose size (d x l) 10 mm x 3 m (3/8 in x 10 ft)
Weight 0.7 kg (1.5 lb)
Service overview
Maintenance and service instructions
The service must only be done by authorized workshops or qualified ser-
vice technicians.
WARNING Polymer hazard
The vanes in this product contain PTFE (a synthetic fluoropolymer). Due to
wear, there might be PTFE particles inside the product. Heated PTFE can
produce fumes which may cause polymer fume fever with flu-like symp-
toms, especially when smoking contaminated tobacco.
Health and Safety recommendations for PTFE must be followed when han-
dling vanes and other components:
►Do not smoke when servicing this product
►PTFE-particles must not come in contact with open fire, glow or heat
►Motor components must be washed with cleaning fluid and not blown
clear with an air line
►Wash your hands before starting any other activity
Replacement of vanes
Replace the vanes in the motor when a power drop of the tool is experienced. If
the vanes are not replaced in time other motor parts may be damaged. For in-
creased life length of the vanes use an oil lubricator to dose oil into the air inlet.

Product information EN G2422-1
8© Atlas Copco Industrial Technique AB - 9839 0485 01
Service recommendations
Preventive maintenance is recommended at regular intervals. See the detailed
information on preventive maintenance. If the product is not working properly,
take it out of service and inspect it.
If no detailed information about preventive maintenance is included, follow
these general guidelines:
• Clean appropriate parts accurately
• Replace any defective or worn parts

G2422-1 EN Installation
© Atlas Copco Industrial Technique AB - 9839 0485 01 9
Installation
Installation requirements
Air quality
• For optimum performance and maximum product life we recommend the
use of compressed air with a maximum dew point of +10°C (50°F). We also
recommend to install an Atlas Copco refrigeration type air dryer.
• Use a separate air filter which removes solid particles larger than 30 mi-
crons and more than 90% of liquid water. Install the filter as close as possi-
ble to the product and prior to any other air preparation units to avoid pres-
sure drop.
Make sure that the hose and couplings are clean and free from dust before
connecting to the tool.
Both lubricated and lubrication free products will benefit from a small
quantity of oil supplied from a lubricator.
Air lubrication guide
Brand Air lubrication
Atlas Copco Optimizer (1 liter) 9090 0000 04
Q8 Chopin 46
Shell Shell Air Tool Oil S2 A 320
Compressed air connection
WARNING Compressed air can cause serious injury
►Always shut off the air supply, drain hose of air pressure and disconnect
the tool from air supply; when not in use, before making any adjustments
to the product - for example changing accessories, or when making re-
pairs.
WARNING Whipping hoses can cause serious injury
►Always make sure that there are no damaged or loose hoses or fittings.
WARNING Compressed Air
High air pressure can cause severe damage and injury.
►Do not exceed maximum air pressure.
For correct air pressure and hose size, see section Technical data.
Make sure that the hose and couplings are clean and free from dust before
connecting to the tool.
Installation instructions
Installation of vibrating tools
It is recommended that a minimum length of 300 mm (12") of flexible hose for
compressed air is inserted between a vibrating tool and the quick-action cou-
pling.

Operation EN G2422-1
10 © Atlas Copco Industrial Technique AB - 9839 0485 01
Operation
Ergonomic guidelines
Consider your workstation as you read through this list of general ergonomic
guidelines and see if you can identify areas for improvement in posture, compo-
nent placement, or work environment.
• Take frequent breaks and change work positions frequently.
• Adapt the workstation area to your needs and the work task.
• Adjust for convenient reach range by determining where parts or tools
should be located to avoid static load.
• Use workstation equipment such as tables and chairs appropriate for the
work task.
• Avoid work positions above shoulder level or with static holding during as-
sembly operations.
• When working above shoulder level, reduce the load on the static mus-
cles by reducing the weight of the tool, using for example torque arms,
hose reels or weight balancers. You can also reduce the load on the static
muscles by holding the tool close to the body.
• Make sure to take frequent breaks.
• Avoid extreme arm or wrist postures, particularly for operations requir-
ing a degree of force.
• Adjust for convenient field of vision by minimizing movement of the eyes
and head during the work task.
• Use the appropriate lighting for the work task.
• Select the appropriate tool for the work task.
• Use ear protection equipment in noisy environments.
• Use high-quality inserted tools or consumables to minimize exposure to ex-
cessive levels of vibration.
• Minimize exposure to reaction forces.
• When cutting:
A cut-off wheel can get stuck if the wheel is either bent or if it is not
guided properly. Make sure to use the correct flanges for cut-off wheels
and avoid bending the wheel during cut-off operation.
• When drilling:
The drill might stall when the drill bit breaks through. Makes sure you
use support handles if the stall torque is too high. The safety standard
ISO11148 part 3 recommends using something to absorb the reaction
torque above 10 Nm for pistol grip tools and 4 Nm for straight tools.
• When using direct-driven screw or nutrunners:
Reaction forces depend on tool setting and joint characteristics. The abil-
ity to bear reaction forces depends on the operator’s strength and pos-
ture. Adapt the torque setting to the operator's strength and posture and
use a torque arm or reaction bar if the torque is too high.
• Use dust extraction system or mouth protection mask in dusty environments.

G2422-1 EN Operation
© Atlas Copco Industrial Technique AB - 9839 0485 01 11
Setting-up instructions
WARNING Risk of Serious Injury or Death
Overspeed can cause serious injury or death!
►Do not manipulate the speed of the tool.
►Do not override the maximum speed marked on the tool.
Testing of the die grinder should only be done by professional technicians. The
technicians must be authorized to test this type of tool and to operate a pneu-
matic system in accordance with national directives.
• Do a free speed check of the tool every day and whenever the tool has been
serviced. Do the free speed check with the grinding equipment removed.
• Use a pressure regulator to prevent a too high air pressure which can cause
overspeed.
• Make sure that connections and the air hose are in good condition.
Legend to page 2
A Do a free speed check
Maximum
20000 r/m
B Maximum air pressure
-7 bar -102 psig
Operating instructions
Visual inspection
Tool and accessories
Inspect the tool and its parts visually before use.
• Collet holder.
• Throttle lever.
• Lever catch.
Look for any damages or oil leakage that can compromise the safety of the tool.
Air installation
Inspect the air installation from the supply point to the tool visually before
use.
• Hose
• Couplings
• System pressure
• Air filter
Look for any damage that can compromise the safety of the tool.

Operation EN G2422-1
12 © Atlas Copco Industrial Technique AB - 9839 0485 01
Operation instructions
WARNING Risk of severe injury
Air under pressure can cause injury.
►Always shut off the air supply when not in use or before any adjustments.
►Drain the hose of air pressure and disconnect the tool from air supply
when not in use or before any adjustments.
WARNING Wrong insert tool can burst and cause serious injury or
death
►Use insert tool with max operating speed higher or equal to the airgrinder
speed
►Do not use other insert tool than specified by the manufacturer (no cut-
ting off wheels or router bits).
• Do not mix mm shanks with inch collets and vice versa.
• Observe a minimum of 10 mm (0.4") axial grip of the shank.
• When attaching mounted wheels or burrs, reduce the overhang by pushing
the shank all the way into the collet. Also do a check of the recommenda-
tions given by the tool manufacturer.
• Observe that increased overhang of shank reduces permissible speed.
• Before starting the machine, make sure that the collet is tightened correctly.
• Do a test run of every newly attached wheel in a safe position for 30 sec-
onds. Use a barrier (such as under a heavy work table) to stop any possible
broken wheel parts. Stop immediately if the vibration is too much.
Legend to page 2
C Operation instructions
D Attach collet and shank
E Press safety catch forward and press trigger to start
F Air hose size: 13 mm (1/2 ")
G Maximum air pressure: - 7 bar (- 102 psig)
Mounted wheel and carbide burr
WARNING Compressed air can cause serious injury
►Always shut off the air supply, drain hose of air pressure and disconnect
the tool from air supply; when not in use, before making any adjustments
to the product - for example changing accessories, or when making re-
pairs.
WARNING Risk of Serious Injury or Death
Wrong insert tool can burst and cause serious injury or death.
►Use an insert tool with a max operating speed higher than or equal to the
tool speed.
►Do not use any other insert tool than specified by the manufacturer (no
cutting off wheels or router bits).
• Use only recommended sizes and types of abrasives.
• Do not use mounting wheels that are chipped or cracked, or may have been
dropped.

G2422-1 EN Operation
© Atlas Copco Industrial Technique AB - 9839 0485 01 13
• Correct mounting is necessary to prevent injury from broken mounted
wheels
• Make sure that the shaft diameter of the accessory is correct for the size of
the collet.
• Do not mix mm shanks with inch collets and vice versa.
• Observe a minimum of 10 mm axial grip of the shank.
• When fitting mounted wheels or burrs, reduce the overhang by pushing the
shank all the way into the collet. (Check also the recommendations given by
the tool manufacturer)
• Observe that increased overhang of shank reduces the permissible speed.
• Before starting the machine, check that the collet is tightened correctly.
• Do a test run of every new mounted wheel in a safe position for 30 seconds.
Use a barrier such as under a heavy work table to stop any possible broken
wheel parts. Stop immediately if the vibration is excessive.

Service EN G2422-1
14 © Atlas Copco Industrial Technique AB - 9839 0485 01
Service
Maintenance instructions
Maintenance and service instructions
The service must only be done by authorized workshops or qualified ser-
vice technicians.
WARNING Polymer hazard
The vanes in this product contain PTFE (a synthetic fluoropolymer). Due to
wear, there might be PTFE particles inside the product. Heated PTFE can
produce fumes which may cause polymer fume fever with flu-like symp-
toms, especially when smoking contaminated tobacco.
Health and Safety recommendations for PTFE must be followed when han-
dling vanes and other components:
►Do not smoke when servicing this product
►PTFE-particles must not come in contact with open fire, glow or heat
►Motor components must be washed with cleaning fluid and not blown
clear with an air line
►Wash your hands before starting any other activity
Service recommendations
Preventive maintenance is recommended at regular intervals. See the detailed
information on preventive maintenance. If the product is not working properly,
take it out of service and inspect it.
If no detailed information about preventive maintenance is included, follow
these general guidelines:
• Clean appropriate parts accurately
• Replace any defective or worn parts
Replacement of vanes
Replace the vanes in the motor when a power drop of the tool is experienced. If
the vanes are not replaced in time other motor parts may be damaged. For in-
creased life length of the vanes use an oil lubricator to dose oil into the air inlet.
Lubrication instructions
Rust protection and cleaning
Water in the compressed air can cause rust. To prevent rust we strongly recom-
mend to install an air dryer.
Water and particles can cause sticking of vanes and valves. This can be pre-
vented by installing an air filter close to the product to avoid pressure drop.
Before longer standstills always protect your tool by adding a few drops of oil
into the air inlet. Run the tool for 5–10 seconds and absorb any access oil at the
air outlet in a cloth.
NOTICE Do not try to clear the air path using sharp tools.
The air inlet is equipped with a strainer. If this is punctured, foreign objects
may harm the valves, resulting in overspeed.

G2422-1 EN Service
© Atlas Copco Industrial Technique AB - 9839 0485 01 15
Lubrication
For flexible spindle extension – When fitting the extended spindle – apply 0.5
cm3 (0.03 cu in) of grease type “Lubricating Engineers LE3752” (or EP grease)
at the bottom of the hole in the collet holder.
Lubricating guide
Use lubricants of good quality. The oils and greases listed in the lubrication ta-
ble are examples of lubricants that can be recommended.
Brand
General purpose
Bearings
BP Energrease LS-EP2
Castrol Spheerol EP L2
Esso Beacon EP2
Q8 Rembrandt EP2
Mobil Mobilegrease XHP 222
Shell Alvania EP2
Texaco Multifak EP2
Molycote BR2 Plus
Dismantling/Assembling instructions
Instructions for vane motor
WARNING Polymer hazard
The vanes in this product contain PTFE (a synthetic fluoropolymer). Due to
wear, there might be PTFE particles inside the product. Heated PTFE can
produce fumes which may cause polymer fume fever with flu-like symp-
toms, especially when smoking contaminated tobacco.
Health and Safety recommendations for PTFE must be followed when han-
dling vanes and other components:
►Do not smoke when servicing this product
►PTFE-particles must not come in contact with open fire, glow or heat
►Motor components must be washed with cleaning fluid and not blown
clear with an air line
►Wash your hands before starting any other activity

Service EN G2422-1
16 © Atlas Copco Industrial Technique AB - 9839 0485 01
Dismantling
Service tools are also included in the Basic Service Tools set. For further infor-
mation see ordering No. 9835 5485 00
Ordering No. Ø D Ø C
4080 0182 01 7 3.5
4080 0182 02 8 4.5
4080 0182 03 9 5.5
4080 0182 04 10 6.5
4080 0182 05 13 8.5
4080 0182 06 16 10.5
4080 0182 07 19 12.5
4080 0182 08 22 15.5
4080 0182 09 24 17.5
4080 0182 10 26 20.5
4080 0182 11 30 25.5
4080 0182 12 35 30.5
4080 0182 13 40 35.5
4080 0182 14 47 40.5
Table1: Dismantling tool Mandrel A
Inspection of motor parts

G2422-1 EN Service
© Atlas Copco Industrial Technique AB - 9839 0485 01 17
Assembling - According to Bäckströms method
Service tools are also included in the Basic Service Tools set. For further infor-
mation see ordering No. 9835 5485 00
Ordering No. Ø D Ø C
4080 0567 04 12.5 5.2
4080 0567 11 14.5 6.5
4080 0567 01 15.5 5.2
4080 0567 05 18.5 6.2
4080 0567 02 18.5 8.2
4080 0567 06 21.5 7.5
4080 0567 03 21.5 8.2
4080 0567 07 25.5 10.5
4080 0567 08 27.5 12.5
4080 0567 09 31.5 15.5
4080 0567 10 34.5 18.5
Table2: Dismantling tool Mandrel B
E: Ball bearing
Testing

Recycling EN G2422-1
18 © Atlas Copco Industrial Technique AB - 9839 0485 01
Recycling
Recycling instruction
When a product has served its purpose it has to be recycled properly. Dismantle
the product and recycle the components in accordance with local legislation.
Batteries shall be taken care of by your national battery recovery organization.

Original instructions
Atlas Copco Industrial
Technique AB
SE-10523 STOCKHOLM
Sweden
Telephone: [phone]
Telefax: [phone]
www.atlascopco.com
© Copyright 2017, Atlas Copco Industrial Technique AB. All rights reserved. Any
unauthorized use or copying of the contents or part thereof is prohibited. This
applies in particular to trademarks, model denominations, part numbers and
drawings. Use only authorized parts. Any damage or malfunction caused by the
use of unauthorized parts is not covered by Warranty or Product Liability.
Out of respect to wildlife and nature, our technical literature is printed on
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