joke Turbo G 180/60 User manual

Surface Technology
Oberflächentechnik
Instruction Manual
TurboHand Grinder
G 180/60 · W 45/40 · W 45/23 · W 90/23
Order no: 0 750 501/ 502/ 503 und 504

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List of contents
1 List of contents Page 02
2 Tips on using the manual Page 02
3 Safety instructions Page 03
4 Warranty/Identification Page 04
5 Device overview Page 05
6 Technical data Page 07
7 Operation Page 08
8 Troubleshooting Page 14
9 Care and maintenance Page 15
10 Telefax form Page 16
Tips on using the manual
Congratulation on the purchase of this device. Please pay attention to the operating instructions,
to be able to use the handpiece eectively - about all - safety.
The symbols used in the manual have the following meaning:
Working and operating processes which must be observed to the letter to exclude any risk to
persons.
The illustrations and diagrams are numbered in sequence within each chapter. Some of these
illustrationshave keys. References to illustrations within the text e. g. (5.1/2) have the following
meaning:
5.1 = Figure 5.1
2 = Position 2 in the key to the figure.
Please feel free to call our customer service department at any time should you encounter tech-
nical problems which are not dealt with in this manual:
Telephone: 0 22 04 / 8 39 - 0
Telefax: 0 22 04 / 8 39 - 60
Internet: www.joke.de
Working and operating processes which must be observed to the letter to avoid any damage to
the device.
Technical information to which the device operator must give special attention.

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Safety instructions
This device has been built according to the latest technical standards and generally accepted
safety regulations. Nevertheless, it can constitute a hazard to the device itself or other equip-
ment during use.
1. Only use the device if in perfect working order and for its intended purpose. You must
always pay attention to the instruction manual and safety instructions therein and be
aware of the risks! Repair any faults which could aect the device’s safety immediately
by yourself or have these repaired.
The unit is designed exclusively for grinding, milling and polishing with the tools listed
and approved in the joke catalogue. Any other use will be deemed to be contrary to its
intended purpose. The manufacturer cannot be held liable for any resulting damages.
The risk is borne solely by the user.
Correct use also includes compliance with the instruction manual and an observation of
the care and maintenance conditions.
2. Keep the instruction manual handy at the device’s place of use.
3. Pay attention to and observe generally applicable statutory and otherwise binding regu-
lations relating to accident prevention and environmental protection in addition to the
information provided in the instruction manual!
4. All personnel commissioned to work on or with the device must have read this instruc-
tion manual, and particularly the safety instructions chapter, before starting work. This
applies especially for personnel who only work with the device occasionally.
5. Stop the device immediately should you notice changes to the device or its operating
behaviour that are relevant to its safety. Have these remedied before restarting work.
6. Do not carry out any modifications, additions or conversions to the device! This also
applies to the installation and adjustment of safety equipment.
7. Spare parts must meet the technical requirements specified by the manufacturer. This
can only be guaranteed with original joke spare parts.
8. Wear safety goggles when working with the handpiece.
9. Personnel undergoing training or in a general apprenticeship should only be allowed to
work with the machine under the constant supervision of an experienced operator!
10. Restrain from any type of work that could jeopardise your safety.
11. The device may only be used if all protective and safety equipment is in place and in
proper working order.
12. Do not leave the device unattended when switched on!!
13. Stop and secure the device immediately in the event of malfunctions! Faults must reme-
died at once.

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Warranty
joke warrant the correct manufacture of every joke Technology GmbH product which is delivered
in accordance with the terms of contract and delivery.
This warranty does not cover damages caused by normal wear and tear, incorrect handling,
negligent use, the fitting of non-original spare parts, inadequate care and/or a failure to comply
with this technical manual.
The device may only be used by appropriately trained personnel. If it is not, all warranty claims
will be forfeited according to the terms of delivery.
Device identification
The manufacturer’s code and type code, CE label and series number can be found on the handle
sleeve.
Waste disposal
Ensure that the device is properly disposed of and is on no account committed
to the domestic waste.
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5Use
The air-driven Turbo hand grinders are intended for grinding and milling. Only the permitted
precision tools for the handpiece may be used in this case.
Permitted tools: refer to joke-Katalog
Figure 5.1 Device overview handgrinders G 180/60 and W 45/40
1 - Tool
2 - Collet
3 - Wrench
4 - Locking pin
5 - Hand grinder
6 - Rotating on-o bush
7 - Exhaust air hose with oil filter
8 - Air supply hose

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Figure 5.2 Device overview - hand grinders W90/23 and W 45/23
1 – Tool
2 – Collet
3 – Wrench
4 – Locking pin, 2 x
5 – Hand grinder
6 – Rotating on-o bush
7 – Exhaust air hose with oil filter
8 – Air supply hose
9 – Allan key
10 – Locking shaft
11 – Cup wheel
12 – Rubber holder (accessory)
13 – Abrasive disc for gluing to rubber disc, 8x (accessory)

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Mode of operation
The Turbo hand grinder is driven by compressed air, which must be treated with oil via a mainte-
nance unit (for example joke Oiljet).
The hand grinder drive consists of a low noise emission rotary vane type motor. The high quality
bearing guarantees a high degree of truth of running.
The drive air is discharged rearwards through an exhaust air line, to the end of which a silencer
and is fitted.
Technical Data
joke TURBO
Hand grinder
G 180/60
Head 180°
W 45/40
Head 45°
W 45/23
Head 45°
W 90/23
Head 90°
Max. speed 60,000 1/min 40,00 1/min 23,000 1/min 23,000 1/min
Power 70 W 70 W 70 W 70 W
Air pressure 4 - 6 bar 4 - 6 bar 4 - 6 bar 4 - 6 bar
Air consumption 165 l/min 165 l/min 165 l/min 165 l/min
Exhaust air backwards backwards backwards backwards
Noise level 80 - 90 dB(A) 80 - 90 dB(A) 90 - 95 dB(A) 90 - 95 dB(A)
Vibration < 0.32 m/s² < 0.32 m/s² < 0.56 m/s² < 0.56 m/s²
Maße Ø 24 x 146 mm Ø 24 x 158 mm Ø 51.5 x 159 mm Ø 46.5 x 152
Lubrication continuous with
oil mist
continuous with
oil mist
continuous with
oil mist
continuous with
oil mist
Weight 200 g 230 g 230 g 230 g
Accessories
Tube package (1.1 m) with coupling
sleeve 1/4“, collet Ø 3 mm (type CHS),
tool set
1 x rubber holder, 2 x cup wheels,
1 x clamping shank,
assortment of consumables, tool set,
tube package 1.1 m with coupling
sleeve 1/4“,
collet Ø 3 mm (type CHS)

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7Maintenance unit and air connection for the Turbo-hand grinder
The compressed air required to drive the Turbo hand grinder must be supplied via a mainte-
nance unit.
Figure 7.1 Maintenance unit joke Oiljet (Best.-Nr. 0 004 050)
Optimum function of the Turbo hand grinder is guaranteed by using the joke Oiljet (Order no. 0
004 050) with a micro oil mist lubricator.
The maintenance unit joke Oiljet consists of:
• automatical water separator
• lter
• pressure gauge
• oil container
• micro oil mist lubricator
• wall mounting.
Please do not make an extension of the original air pipe or the spiral coiled tube whereby the
diameter will be reduced. Thus, the oil cannot flow to the motor and it gets dry!
Technical data for maintenance unit joke-Oiljet:
max. volume flow: 1.200 l/min
max. inlet pressure: 16 bar
adjustment range: 0 - 12 bar
The maintenance unit must consist of the following
functional units:
• Water separator and lter
• Pressure gauge
• Oil mist lubricator (micro oil mist lubricator)
For other accessories, refer to the joke catalogue.

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Operating principle of the oil mist lubricator
The micro oil mist lubricator ensures uniform, rapid and precisely dosed hand grinder lubrication.
The oil mist lubricator is set to 3 drops per minute.
The special air supply makes it possible to reduce the size of the oil particles. The latter can
be conveyed in the airflow over wide distances as micro mist. They are scarcely deposited. All
surfaces with which they come into contact are intensively and very evenly moistened. An even,
stable oil film results on the bearing surfaces with a thickness that can be rapidly and precisely
adjusted.
Setting up and connecting the maintenance unit
1. On the maintenance unit, check whether:
• the condensate drainage screw is closed;
Turn to the right to close.
• dthe pressure adjustment screw is open; Turn to the left to open.
2. Fill the oil container up to the mark with joke high performance lubricant X 73012.
The oil level must not reach higher than the deflector of the microoil mist lubricator .
Order no. for the lubricant in dierent container sizes, refer to the joke catalogue.
Take care that the air flows through the housing in the direction indicated by the arrow.
The label on the container shows the minimal and maximal oil
level. If the level of oil falls below the minimum oil level, it must
be refilled.
Figure 7.2 View from above maintenance unit
Adjusting screw
Refill screw

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Figure 7.3 Setting hand grinders G 180/60 into operation
2. Lay the hose with the end lter freely; do not kink!
3. Set a pressure of 6 bar on the maintenance unit. The hand grinder is ready for operation.
Connecting the hand grinder
1. Connect the air supply hose of the hand grinder to the maintenance unit.
A hose length of more than 2 m does not ensure any continuous lubrication of the hand grinder
since the oil already deposits in the inside of the hose.
Setting hand grinders G 180/60 and W 45/40 into operation
1. Secure the mandrel in the hand grinder with the locking pin (7.3/3).
2. Insert tool (7.3/1) in the collet and screw tight with wrench (7.3/2).
3. Switch on the speed by turning knurled ring (7.3/4).

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Figure 7.4 Setting hand grinders W 90/23 into operation
Setting hand grinders W 45/23 and W 90/23 into operation
When using a locking shaft (7.4/2):
1. Secure the mandrel in the hand grinder with a locking pin.
2. Insert the second locking pin through the locking shaft (7.4/2) and screw the locking shaft into
the hand grinder.
3. Screw tool (7.4/1) into the locking shaft.
4. If necessary, cover (7.4/6) can be removed after loosening a headless pin with the Allan key
(7.4/5).
When using a collet, set the hand grinder into operation as described in the following section.

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Notes on operation
• The recommended air pressure for operation of the hand grinder is 6 bar.
Higher pressure may result in damage to the hand grinder.
• When immobile, the mandrel must be treated particularly carefully. Under no circumstances
must the mandrel be knocked, since the high precision bearings, which are necessary for
operation, will be damaged as a result. Impact stress in the immobile state results in perma
nent deformation of the bearing races.
• Use only light pressure when grinding and milling with the hand grinder.
• Pay attention to the permitted cutting speeds and the tool manufacturer’s prescriptions befo
reusing the tools.
• Check that the tool is seated rmly and securely tighten the collet with the prescribed keys.
• Regularly check the maintenance unit. If condensed water and dirt are present, drain the
condensate and clean the filter (refer to Care/maintenance section).
Wear protective goggles!
Figure 7.5 changing collet
Changing the collets
hand grinders W 45/40, W 45/23 und W 90/23
For all hand-grinders W 45/23 and W 90/23 the hexagon insert must be loosen first like (pic. 5.2/9).
Please fix the mandrel with a lock bolt (5.2/4) and loosen the collet (5.2/4) with the hook wrench.
After loosen the collet it can be replaced by a new one.

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For usable tools, refer to the joke catalogue
• Every grinding point has yweight and must be dressed before use. The dressing process
begins at a low speed and is constantly repeated until the device has reached the highest
speed.
A joke diamond conditioner is recommended for dressing.
• Tungsten carbide burs, diamond tools, drills and graving tools
It is essential to check truth of running with these tools. Errors in truth of running cannot be
remedied by dressing. A certain possibility for cor-rection exists only when the shaft of the
tool is rotated into the loosened collet. If the necessary truth of running cannot be achieved,
another tool must be selected.
The resulting flyweight may endanger the user and also rapidly destroy the mandrel bearings.
It is therefore recommended to only use tungsten carbide burs and diamond tools, for which the
manufacturer guarantees the necessary truth of running.
Tool receptions
• The Turbo hand grinders are intended only for manual use.
• The tool reception is designed in such a way that tools with shafts of a Ø up to 3 mm can be
fitted into the collets.
• When inserting the collets, care must be taken to ensure meticulous cleanliness of the collet
itself and the inner cone. Only in this way can optimum truth of running be achieved. Fur-
thermore, a distance of approx. 1 mm is necessary between the tool shaft and the base of the
mandrel. Take care in this case to always select the largest possible shaft Ø and the shortest
possible collet – grinding point distance (resulting in safety and stability).

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Troubleshooting
Malfunction Possible cause Remedy
Tool does not turn Hand grinder not switched on
at the rotating ring Turn the rotating ring
Hose lines kinked Eliminate the kink
Air pressure controller on the
maintenance unit not opened.
Set pressure controller to 6
bar.
Collect faulty Change collet
Bearing in headpiece faulty Change headpiece
Maintenance unit faulty Send to joke service
Motor läuft trocken Vane worned out Oil can‘t be supplied optimal
Operation with a spiral hose Oil can‘t be supplied optimal
Operation hose is to long
(more than 2 m) Oil can‘t be supplied optimal

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Care
Clean the hand grinder if required with a soft brush/paintbrush or a dry cloth.
Otherwise, the hand grinder is maintenance-free.
Maintenance
Changing the oil filter on the exhaust air hose of the hand grinder.
1. Unscrew the lter housing on the exhaust air hose.
2. Remove the filter from the housing and change..
3. Screw the filter housing back on to the hose.
Draining condensate from the air filter of the maintenance unit.
1. Unscrew the condensate container
2. Screw o the air filter and change.
Take care that the filter mounting and the loose seal are rein-stalled in an identical position.
3. Screw the condensate container back in and perform a functional test.
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Turbo hand grinder G 180/60 Order no. 0 750 501 
Turbo hand grinder W 45/40 Order no. 0 750 502 
Turbo hand grinder W 45/23 Order no. 0 750 503 
Turbo hand grinder W 90/23 Order no. 0 750 504 
Maintenance unit joke Oiljet Order no. 0 004 050 
Date Signature
To
joke Technology GmbH
Service-department
Fax: 0 22 04 / 8 39 - 60
Sender:
Company
Name/Department
Customer-no.
Street
Post code/town
Please send us the spare parts drawing with parts list for the following devices:
as a printout (see above for address,
per fax,
as a pdf file to my email address.

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joke Technology GmbH
Asselborner Weg 14 -16
D-51429 Bergisch Gladbach
Tel. [phone] / 8 39-0
Fax [phone] / 8 39-60
Mail [email protected]
Web www.joke.de
© Copyright joke Technology GmbH • October 2012 • Changes due to technical progress, errors and printing errors
reserved • Reproduction, also partial, only with prior written permission.
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