K-EIKO EGA100 User manual

MODEL EGA100
EGA115
EGA125
•Compact body
•Convenient spindle lock
•Powerful motor
•Easy-to-use slide switch
INDUSTRIAL POWER TOOLS
100mm (4")
115mm (41/2") Disc Grinder
125mm (5")
OPERATOR'S MANUAL
Please retain this information for future reference
WARNING: THE SAFETY INFORMATION
GIVEN INSIDE MUST BE READ AND
UNDERSTOOD BY ANY PERSON
USING, INSTALLING, REPAIRING
OR MAINTAINING THESE
TOOLS.

2
Symbols
The following show symbols used for the machine. Be
sure that you understand their meaning before use.
Read instruction manual.
Wear safety glasses.
GENERAL SAFETY RULES
WARNING!
Failure to follow all instructions listed below may result in
electric shock, fire and/or serious injury.
The term “power tool” in all of the warnings listed below
referstoyourmainsoperated(corded)powertoolorbattery
operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
1) Work area
a) Keep work area clean and well lit.
Cluttered and 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 of 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.
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 safety equipment. Always wear eye protection.
Safety equipment such as dust mask, non-skid safety
shoes, hard hat, or hearing protection used for
appropriate conditions will reduce personal injuries.
c) Avoid accidental starting. Ensure the switch is in
the off position before plugging in.
Carrying power tools with your finger on the
switch or plugging in 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 these devices can reduce dust related
hazards.
4) Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your application.
The correct power tool will do the job better and
safer at the rate for which it was designed.
b) Do not use the power tool if the switch does not
turn it on and off.
Any power tool that cannot be controlled with the
switch is dangerous and must be repaired.
c) Disconnect the plug from the power source 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
tools operation.
If damaged, have the power tool repaired before
use.
Many accidents are caused by poorly maintained
power tools.

3
SPECIFICATIONS
STANDARD ACCESSORIES
(1) Wrench ........................................................................1
(2) Side handle ................................................................1
Standard accessories are subject to change without
notice.
APPLICATIONS
䡬 Removal of casting fin and finishing of various types
of steel, bronze and aluminum materials and castings.
䡬Grinding of welded sections or sections cut by
means of a cutting torch.
䡬Grinding of synthetic resins, slate, brick, marble, etc.
PRIOR TO OPERATION
1. Power source
Ensure that the power source to be utilized conforms
to the power requirements specified on the product
nameplate.
2. Power switch
Ensure that the power switch is in the OFF position.
If the plug is connected to a receptacle while the
power switch is in the ON position, the power tool
will start operating immediately, which could cause
a serious accident.
3. Extension cord
When the work area is removed from the power
source, use an extension cord of sufficient thickness
and rated capacity. The extension cord should be
kept as short as practicable.
4. Fitting and adjusting the wheel guard
The wheel guard is a protective device to prevent
injury should the depressed center wheel shatter during
operation. Ensure that the guard is properly fitted and
fastened before commencing grinding operation.
By slightly loosening the setting screw, the wheel
guard can be turned and set at any desired angle
for maximum operational effectiveness. Ensure that
the setting screw is thoroughly tightened after
adjusting the wheel guard.
5. Ensure that mounted wheels and points are fitted
in accordance with the manufacturer’s instructions.
Ensure that the depressed center wheel to be utilized
is the correct type and free of cracks or surface
defects. Also ensure that the depressed center wheel
is properly mounted and the wheel nut is securely
tightened, Refer to the section on “Depressed Center
Wheel Assembly”
Ensure that blotters are used when they are provided
with the bonded abrasive product and when they
are required.
Do not use separate reducing bushings or adaptors
to adapt large hole abrasive wheels.
Model EGA100 EGA115 EGA125
Voltage (by areas) 110V, 230V
Power Input* 650 W
No-load speed 11000 min-1 10000 min-1
Outer dia. × hole dia. 100 ×16 mm 115 ×22 mm 125 ×22 mm
Wheel Peripheral speed 72 m/s 80 m/s
Weight (Only main body) 1.4 kg
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 and in the
manner intended for the particular type of power
tool, taking into account the working conditions
and the work to be performed.
Use of the power tool for operations different from
intended could result in a hazardous situation.
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.
PRECAUTION
Keep children and infirm persons away.
When not in use, tools should be stored out of
reach of children and infirm persons.
PRECAUTIONS ON USING DISC GRINDER
1. Never operate these power tools without Wheel
Guards.
2. Check that speed marked on the wheel is equal to
or greater than the rated speed of the grinder.
Use only depressed center wheels rated at 80m/s
(72m/s only for 100 mm disc grinders) or more.
3. Ensure that the wheel dimensions are compatible
with the grinder and that the wheel fits the spindle.
4. Abrasive wheels shall be stored and handled with
care in accordance with manufacturer’s instructions.
5. Inspect the depressed center wheel before use, do
not use chipped, cracked or otherwise defective
products.
6. Always hold the body handle and side handle of
the power tool firmly. Otherwise the counterforce
produced may result in inaccurate and even
dangerous operation.
7. Do not use cutting-off wheels for side grinding.
8. Do not use of separate reducing bushings or adapters
to adapt large hole abrasive wheels.
9. The wheel continues to rotate after the tool is
switched off.

4
For tools intended to be fitted with threaded hole
wheel, ensure that the thread in the wheel is long
enough to accept the spindle length.
Do not use cutting off wheel for side grinding.
6. Conducting a trial run
Ensure that the abrasive products is correctly
mounted and tightened before use and run the tool
at no-load for 30 seconds in a safe position, stop
immediately if there is considerable vibration or if
other defects are detected.
If this condition occurs, check the machine to
determine the cause.
7. Confirm the push button.
Confirm that the push button is disengaged by
pushing push button two or three times before
switching the power tool on (See Fig. 2).
8. Fixing the side handle
Screw the side handle into the gear cover.
PRACTICAL GRINDER APPLICATION
1. Pressure
To prolong the life of the machine and ensure a
first class finish, it is important that the machine
should not be overloaded by applying too much
pressure. In most applications, the weight of the
machine alone is sufficient for effective grinding.
Too much pressure will result in reduced rotational
speed, inferior surface finish, and overloading which
could reduce the life of the machine.
2. Grinding angle
Do not apply the entire surface of the depressed
center wheel to the material to be ground. As
shown in Fig. 1, the machine should be held at an
angle of 15° – 30° so that the external edge of the
depressed center wheel contacts the material at an
optimum angle.
AB
15°– 30°
Fig. 1
3. To prevent a new depressed center wheel from
digging into the workpiece, initial grinding should
be performed by drawing the grinder across the
workpiece toward the operator (Fig. 1 direction B).
Once the leading edge of the depressed center
wheel is properly abraded, grinding may be
conducted in either direction.
4. Precautions immediately after finishing operation
The wheel continues to rotate after the tool is
switched off.
After switching off the machine, do not put it down
until the depressed center wheel has come to a
complete stop. Apart from avoiding serious
accidents, this precaution will reduce the amount
of dust and swarf sucked into the machine.
CAUTIONS
䡬Check that the work piece is properly supported.
䡬Ensure that ventilation openings are kept clear when
working in dusty conditions.
If it should become necessary to clear dust, first
disconnect the tool from the mains supply (use non-
metallic objects) and avoid damaging internal parts.
䡬Ensure that sparks resulting from use do not create
a hazard e.g. do not hit persons, or ignite flammable
substances.
䡬Always use protective safety glasses and hearing
protectors, use other personal protective equipment
such as gloves, apron and helmet when necessary.
䡬Always use eye and ear protection.
Other personal protective equipment such as dust
mask, gloves, helmet and apron should be worn
when necessary.
If in doubt, wear the protective equipment.
䡬When the machine is not use, the power source
should be disconnected.
ASSEMBLING AND DISASSEMBLING THE
DEPRESSED CENTER WHEEL (Fig. 2)
CAUTION Be sure to switch OFF and disconnect the
attachment plug from the receptacle to avoid
a serious accident.
1. Assembling (Fig. 2)
(1) Turn the disc grinder upsidedown so that the spindle
is facing upward.
(2) Align the across flats of the wheel washer with the
notched part of the spindle, then attach them.
(3) Fit the protuberance of the depressed center wheel
onto the wheel washer.
(4) Screw the wheel nut onto the spindle.
(5) While pushing the push button with one hand, lock
the spindle by turning the depressed center wheel
slowly with the other hand.
Tighten the wheel nut by using the supplied wrench
as shown in Fig. 2.
2. Disassembling
Follow the above procedures in reverse.
Fig. 2
Wrench
Depressed
center wheel
Wheel nut
Wheel washer
Spindle Wheel guard
Push button

5
CAUTIONS
䡬Comfirm that the depressed center wheel is mounted
firmly.
䡬Confirm that the push button is disengaged by
pushing push button two or three times before
switching the power tool on.
MAINTENANCE AND INSPECTION
1. Inspecting the depressed center wheel
Ensure that the depressed center wheel is free of
cracks and surface defects.
2. Inspecting the mounting screws
Regularly inspect all mounting screws and ensure
that they are properly tightened. Should any of the
screws be loose, retighten them immediately. Failure
to do so could result in serious hazard.
3. Inspecting the carbon brushes (Fig. 3)
The motor employs carbon brushes which are
consumable parts. Since an excessively worn carbon
brush can result in motor trouble, replace the carbon
brushes with new ones having the same carbon
brush No. shown in the figure when it becomes
worn to or near the “wear limit”. In addition, always
keep carbon brushes clean and ensue that they
slide freely within the brush holders.
5 mm
12
mm
21
Fig. 3
4. Replacing carbon brushes:
Disassemble the brush caps with a slotted-head
screwdriver. The carbon brushes can then be easily
removed.
5. Maintenance of the motor
The motor unit winding is the very “heart” of the
power tool. Exercise due care to ensure the winding
does not become damaged and/or wet with oil or
water.
6. Service parts list
CAUTION
Repair, modification and inspection of K-EIKO Power
Tools must be carried out by a K-EIKO Authorized
Service Center.
This Parts List will be helpful if presented with the
tool to the K-EIKO Authorized Service Center when
requesting repair or other maintenance.
In the operation and maintenance of power tools,
the safety regulations and standards prescribed in
each country must be observed.
MODIFICATIONS
K-EIKO Power Tools are constantly being improved
and modified to incorporate the latest technological
advancements.
Accordingly, some parts may be changed without
prior notice.
NOTE
Due to K-EIKO’s continuing program of research and
development, the specifications herein are subject to
change without prior notice.
IMPORTANT
Correct connection of the plug
The wires of the main lead are coloured in accordance
with the following code:
Blue: -Neutral
Brown: -Live
As the colours of the wires in the main lead of this tool
may not correspond with the coloured markings
identifyingtheterminalsinyourplugproceedas follows:
Thewirecolouredbluemustbeconnectedtotheterminal
marked with the letter N or coloured black. The wire
colouredbrownmustbeconnectedtothe terminal mark-
ed with the letter L or coloured red. Neither core must be
connected to the earth terminal.
NOTE
This requirement is provided according to BRITISH
STANDARD 2769: 1984.
Therefore, the letter code and colour code may not
be applicable to other markets except The United
Kingdom.
Information concerning airborne noise and vibration
The measured values were determined according to
EN50144.
The typical A-weighted sound pressure level: 88 dB (A)
The typical A-weighted sound power level: 101 dB (A)
Wear ear protection.
The typical weighted root mean square acceleration
value does not exceed 2.5 m/s2.
Only for EU countries
Do not dispose of electric tools together with
household waste material!
In observance of European Directive 2002/96/EC on
waste electrical and electronic equipment and its
implementation in accordance with national law,
electric tools that have reached the end of their life
must be collected separately and returned to an
environmentally compatible recycling facility.
Wear limit
No. of carbon brush

6
501
502
12
34
67
5
8
9
10
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
38
37
39 40 41 42 43
44 45
46
47 48 49
50 51 52 53
54
55
56
57
58
11
12
14 15 16
13
Item Part Name Q’ty
No.
1TAPPING SCREW D5 ×25 1
2GUARD PLATE 1
3PUSHING BUTTON 1
4GEAR COVER ASS’Y 1
5SPECIAL NUT M7 1 6 PINION 1
7SLOTTED HD. SCREW
(SEAL LOCK) M4 ×10 2
8BALL BEARING 608VVC2PS2L 1
9INNER COVER 1
10 ARMATURE 1
11 FAN GUIDE 1
12 HEX. HD. TAPPING SCREW
D4 ×70 2
13 STATOR 1
14 DUST SEAL 2
15 BALL BEARING 626VVC2PS2L 1
16 RUBBER BUSHING 1
17 LOCK PIN 1
18 RETAINING RING FOR D11 SHAFT 1
19 WAVE WASHER 1
20 GEAR 1
21 SEAL LOCK SCREW
(W/SP. WASHER) M4 ×10 3
22 BEARING COVER (B) 1
23 BALL BEARING 6001VVCMPS2L 1
24 FELT PACKING 1
25 PACKING GLAND 1
26 SEAL LOCK SCREW
(W/SP. WASHER) M4 ×12 4
27 WOODRUFF KEY 1
28 SPINDLE 1
29 MACHINE SCREW
(W/SP. WASHER) M5 ×16 2
30 SET PLATE 1
31 WHEEL GUARD ASS’Y 1
32 WHEEL WASHER 1
33 D. C. WHEELS 1
34 WHEEL NUT M14 1
35 GEAR AND PINION SET 1 36 SLIDE KNOB 1
37 HOUSING ASS’Y 1
38 NAME PLATE 1
39 EARTH TERMINAL 1
40 TERMINAL 1
41 NOISE SUPPRESSOR 1
42 SWITCH HOLDER 1
Item Part Name Q’ty
No.
43 PILLAR TERMINAL 1
44 SPRING 1
45 SLIDE BAR 1
45 SLIDE BAR 1
46 LABEL 1
47 BRUSH CAP 2
48 CARBON BRUSH 2
49 BRUSH HOLDER 2
50 SWITCH 1
51 MACHiNE SCREW (W/WASHER)
D3.5 ×6 2
52 TERMINAL 1
53 CORD CLIP 1
54 TAPPING SCREW (W/FLANGE)
D4 ×16 1
55 CORD ARMOR 1
56 TAIL COVER 1
57 TAPPING SCREW (W/FLANGE)
D4 ×45 4
58 CORD 1
501 WRENCH 1
502 SIDE HANDLE 1

7

611
Code No. C99158311
Printed in China
EC DECLARATION OF CONFORMITY
We declare under our sole responsibility that this
product is in conformity with standards or
standardized documents EN60745, EN55014 and
EN61000-3 in accordance with Council Directives
73/23/EEC, 89/336/EEC and 98/37/EC.
Manufactured for
KENNEDY TOOLS
Wigston Works, Leicester, England.
ISO 9002 REGISTERED COMPANY
Signed:
Date: 30 November 2006
Name: Martin Cooke
Position: Director, The Kennedy Group Ltd.
QUALITY GUARANTEE & WARRANTY
K–EIKO INDUSTRIAL POWER TOOLS carry one years manufacturers warranty.
K–EIKO INDUSTRIAL POWER TOOLS are designed & manufactured
to the highest standards & specifications
Assuring the quality and performance required by all sectors of industry.
K–EIKO INDUSTRIAL POWER TOOLS are fully guaranteed against
faulty materials & workmanship
Should they be found to be defective, they will either be repaired or replaced free of charge
(fair wear and tear and/or misuse excepted).
Please retain supplier invoice as proof of purchase.
Manufactured For:
KENNEDY TOOLS
Wigston Works, Leicester, England.
ISO 9001 REGISTERED COMPANY
AVAILABLE FROM YOUR DISTRIBUTOR