Atlas Copco G2424-S120 Instruction sheet

G2424-S120
Printed Matter No. 9839 1936 01
Publication Date 2019-11-08
Valid from Serial No. B1790001 Product Instructions
G2424-S120
(12500 r/min)
(12500 rpm)
8423031260
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

2© Atlas Copco Industrial Technique AB - 9839 1936 01
Table of Contents
Product Information................................................................................................4
General Information ..........................................................................................4
Safety signal words ...............................................................................4
Warranty ................................................................................................4
ServAid ..................................................................................................4
Website..................................................................................................5
Safety Data Sheets MSDS/SDS............................................................5
Installation of Vibrating Tools ................................................................5
Country of Origin ...................................................................................5
Dimensional Drawings...........................................................................5
Overview...........................................................................................................5
Design and function...............................................................................5
Technical Product Data .........................................................................5
Service Overview..............................................................................................6
Replacement of vanes...........................................................................6
Maintenance and service instructions ...................................................6
Service recommendations .....................................................................6
Installation ...............................................................................................................7
Installation Requirements .................................................................................7
Air Quality ..............................................................................................7
Air Lubrication Guide .............................................................................7
Compressed Air Connection..................................................................7
Installation Instructions .....................................................................................7
Visual inspection - Tool and accessories ..............................................7
Installation of Vibrating Tools ................................................................8
Operation .................................................................................................................9
Ergonomic guidelines .......................................................................................9
Operating Instructions.....................................................................................10
Tool operation overview ......................................................................10
Operation instructions..........................................................................11
Service ...................................................................................................................12
Maintenance Instructions................................................................................12
Maintenance and service instructions .................................................12
Service recommendations ...................................................................12
Replacement of vanes.........................................................................12
Lubrication Instructions...................................................................................12
Rust protection and cleaning ...............................................................12
Lubrication ...........................................................................................12
Lubricating guide .................................................................................13
Dismantling/Assembling Instructions ..............................................................13
Instructions for complete tool...............................................................13
Instructions for vane motor ..................................................................14

3
© Atlas Copco Industrial Technique AB - 9839 1936 01
Recycling ...............................................................................................................17
Environmental Regulations.............................................................................17

Product Information EN G2424-S120
4© Atlas Copco Industrial Technique AB - 9839 1936 01
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 regarding 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 following meanings:
DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or se-
rious 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 ex-
pire 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 adjustment/overhaul during
standard tools maintenance typical for that period (expressed in time, operation hours or other-
wise).
■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 performed 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 mainte-
nance schedules and follow the correct instructions.
■Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.
Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover
contracts. For further information contact your local Service representative.
For electrical motors:
■Warranty will only apply when the electric motor has not been opened.
ServAid
ServAid is a portal that is continuously updated and contains Technical Information, such as:
■Regulatory and Safety Information
■Technical Data

G2424-S120 EN Product Information
© Atlas Copco Industrial Technique AB - 9839 1936 01 5
■Installation, Operation and Service Instructions
■Spare Parts Lists
■Accessories
■Dimensional Drawings
Please visit: https://servaid.atlascopco.com.
For further Technical Information, please contact your local Atlas Copco representative.
Website
Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on
the Atlas Copco website.
Please visit: www.atlascopco.com.
Safety Data Sheets MSDS/SDS
The Safety Data Sheets describe the chemical products sold by Atlas Copco.
Please consult the Atlas Copco website for more information www.atlascopco.com/sds.
Installation of Vibrating Tools
We recommend using a minimum length of 300 mm (12") of flexible hose for compressed air between a vi-
brating tool and the quick-action coupling.
Country of Origin
For the Country of Origin, please refer to the information on the product label.
Dimensional Drawings
Dimensions Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.
Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.
Overview
Design and function
This die grinder is intended for mounted wheels and rotary burrs only. This model is lubricated. The ma-
chine, its attachments and accessories must only be used for the purpose for which they were designated,
all other use is prohibited.
■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 Product Data
Technical Product Data can be found on either ServAid, or the Atlas Copco website.
Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

Product Information EN G2424-S120
6© Atlas Copco Industrial Technique AB - 9839 1936 01
Service Overview
Replacement of vanes
Replace the vanes in the motor when a power drop of the tool is experienced. If the vanes are not re-
placed in time other motor parts may be damaged. For increased life length of the vanes use an oil lubri-
cator to dose oil into the air inlet.
Maintenance and service instructions
The service must only be done by authorized workshops or qualified service 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 symptoms, especially when smoking contaminated tobacco.
Health and Safety recommendations for PTFE must be followed when handling vanes and other com-
ponents:
►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

G2424-S120 EN Installation
© Atlas Copco Industrial Technique AB - 9839 1936 01 7
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 microns and more than 90% of
liquid water. Install the filter as close as possible to the product and prior to any other air preparation
units to avoid pressure drop.
For impulse/impact tools make sure to use lubricators adjusted for these tools. Regular lubricators will
add too much oil and therefore decrease the tool performance due to too much oil in the motor.
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 lu-
bricator.
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 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.
►Always use the correct hose size and air pressure for the tool.
WARNING Compressed Air
High air pressure can cause severe damage and bodily injury.
►Do not exceed maximum air pressure.
►Make sure that there are no damaged or loose hoses or fittings.
For correct air pressure and hose size, see the Technical Product Data on - https://
servaid.atlascopco.com or www.atlascopco.com.
Make sure that the hose and couplings are clean and free from dust before connecting to the tool.
Installation Instructions
Visual inspection - Tool and accessories
Inspect the tool and its parts visually before use.
■Collet holder.

Installation EN G2424-S120
8© Atlas Copco Industrial Technique AB - 9839 1936 01
■Throttle lever.
■Lever catch.
Look for any damages or oil leakage that can compromise the safety of the tool.
Installation of Vibrating Tools
We recommend using a minimum length of 300 mm (12") of flexible hose for compressed air between a vi-
brating tool and the quick-action coupling.

G2424-S120 EN Operation
© Atlas Copco Industrial Technique AB - 9839 1936 01 9
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, component 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 assembly operations.
■When working above shoulder level, reduce the load on the static muscles 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 requiring 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 excessive 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 ab-
sorb 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 ability to bear reaction forces
depends on the operator’s strength and posture. 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.

Operation EN G2424-S120
10 © Atlas Copco Industrial Technique AB - 9839 1936 01
Operating Instructions
Tool operation overview
A Free speed check
B Maximum speed at 6.3 bar 90 psig
12500 r/m rpm
C Operation instructions
D Attach collet (1) and shank (2)
E Press safety catch forward (1) and press trigger to
start (2)
F Air hose size: 13 mm (1/2 ")
G Maximum air pressure: - 6.3 bar (- 90 psig)
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 au-
thorized to test this type of tool and to operate a pneumatic 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.

G2424-S120 EN Operation
© Atlas Copco Industrial Technique AB - 9839 1936 01 11
■Make sure that connections and the air hose are in good condition.
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.
►Always use the correct hose size and air pressure for the tool.
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.
■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 (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 recommendations 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 seconds. Use a barrier (such as
under a heavy work table) to stop any possible broken wheel parts. Stop immediately if the vibration
is too high.

Service EN G2424-S120
12 © Atlas Copco Industrial Technique AB - 9839 1936 01
Service
Maintenance Instructions
Maintenance and service instructions
The service must only be done by authorized workshops or qualified service 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 symptoms, especially when smoking contaminated tobacco.
Health and Safety recommendations for PTFE must be followed when handling vanes and other com-
ponents:
►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 re-
placed in time other motor parts may be damaged. For increased life length of the vanes use an oil lubri-
cator 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 recommend to install an air dryer.
Water and particles can cause sticking of vanes and valves. This can be prevented by installing an air fil-
ter 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.
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.

G2424-S120 EN Service
© Atlas Copco Industrial Technique AB - 9839 1936 01 13
Lubricating guide
Use lubricants of good quality. The oils and greases listed in the lubrication table are examples of lubri-
cants 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 complete tool
Dismantling
Inspection

Service EN G2424-S120
14 © Atlas Copco Industrial Technique AB - 9839 1936 01
Assembly
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 symptoms, especially when smoking contaminated tobacco.
Health and Safety recommendations for PTFE must be followed when handling vanes and other com-
ponents:
►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

G2424-S120 EN Service
© Atlas Copco Industrial Technique AB - 9839 1936 01 15
Dismantling
Service tools are also included in the Basic Service Tools set. For further information see ordering No.
9835 5485 00
Dismantling tool Mandrel A
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
Inspection of motor parts

Service EN G2424-S120
16 © Atlas Copco Industrial Technique AB - 9839 1936 01
Assembling - According to Bäckströms method
E: Ball bearing
Service tools are also included in the Basic Service Tools set. For further information see ordering No.
9835 5485 00
Dismantling tool Mandrel B
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

G2424-S120 EN Recycling
© Atlas Copco Industrial Technique AB - 9839 1936 01 17
Recycling
Environmental Regulations
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 2019, 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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