Lukas AMIN 12-125 TWH User manual

17.10.2008 Page 1 • AMIN 12-125T WH •
OPERATION INSTRUCTIONS
AMIN 12-125 TWH

17.10.2008 Page 2 • AMIN 12-125T WH •
Index
1 Safety Instructions..................................................................................................... 3
1.1 General safety instructions ........................................................................................ 3
1.2 Safety instructions for grinders .................................................................................. 3
1.3 Obligations of the owner operator.............................................................................. 6
1.4 Obligations of the personnel...................................................................................... 7
1.5 Warranty and liability ................................................................................................. 7
1.6 Explanation of the symbols........................................................................................ 7
1.7 Complying with the environmental protection regulations .......................................... 9
2 Intended Use............................................................................................................. 9
3 Installation................................................................................................................. 9
4 Starting Up .............................................................................................................. 10
4.1 Changing the abrasive wheel .................................................................................. 11
4.2 Adjusting the guard ................................................................................................. 12
4.3 Changing to left-handed operation .......................................................................... 13
5 Handling.................................................................................................................. 14
6 Disassembly – Assembly......................................................................................... 15
6.1 Spare parts drawing ................................................................................................ 19
6.2 Dimensions sheet.................................................................................................... 26
7 Maintenance and Servicing ..................................................................................... 26
7.1 Oil Change .............................................................................................................. 27
8 Help With Problems................................................................................................. 28
9 Scope of Supply ...................................................................................................... 29
10 Accessories to Special Order .................................................................................. 29
11 Storage ................................................................................................................... 30
12 Technical Data ........................................................................................................ 30
13 Statement of Conformity.......................................................................................... 31
14 Warranty Card......................................................................................................... 32

17.10.2008 Page 3 • AMIN 12-125T WH •
1 Safety Instructions
1.1 General safety instructions
Read the operation instructions before starting work and follow the
instructions in operation.
In general, the owner operator of the machine is responsible for ensuring a flawless state with regard
to operation and compliance with the safety regulations. The machine has been built to the state of
the art and recognized safety rules. Nonetheless, there can be hazards to life and limb to the
operator or thirds parties when it is used, or else damage could be done to the machine or other
assets.
Only use the machine:
●for the intended purpose,
●in a flawless state regarding safety.
Note the technical data of the machine and the ambient temperatures. The intended use of the
machine is described in this documentation in section Intended Use and must be followed. The basic
precondition for safe working with and trouble-free operation of the machine is a knowledge of the
underlying safety instructions and the safety regulations. In addition, the rules and regulations that
apply at the place of use regarding accident prevention, the setting up of electrical and mechanical
systems and radio interference suppression are to be followed. Pay attention to the cleanliness of
the workplace in all maintenance and repair work. You may not eat or drink while working. If you
make any changes on your initiative that go beyond the intended use, the warranty shall be null and
void and the manufacturer shall have no liability whatsoever.
●The machines are not insulated against contact with electric cables and may not be used
in an atmosphere with a risk of explosion.
It is essential to follow the operation instructions, especially the safety symbols and safety
instructions on the machine and in the documentation.
1.2 Safety instructions for grinders
●Only use approved abrasive wheels with the appropriate diameter of shaft.
●The approved working speed of the abrasive wheel must be higher than the speed
of the grinder.
●Never use a grinder that is not in a proper working state or which has defective components.
●The abrasive wheels must stored and handled with care in accordance with the instructions of
the manufacturer.
●Check the abrasive wheel for damage before using it on the grinder. Never use abrasive wheels
that are chipped, cracked or damaged in any other way.
●The machine must be switched off in the event of a power failure.

17.10.2008 Page 4 • AMIN 12-125T WH •
●When connecting or disconnecting the grinder it is essential to ensure that the operating lever is
not and cannot be operated.
●Disconnect the machine from the power supply when changing the tool.
●Never remove any safety devices mounted on the machine and ensure that they are attached
and working properly before you switch the machine on.
●Guards or covers are to be adjusted such that they direct sparks and grinding particles away
from the body.
●Strong vibration can be caused by machine tools that are not attached properly or are damaged.
●Do not use abrasive cutting-off wheels (on machines with a collet chuck).
●Never exceed the maximum permissible working speed. It must be checked regularly.
●Before starting up the machine, check that the abrasive wheel has been attached correctly and
done up tightly. Carry out a test run for 30 seconds when the machine is in a safe position and
not under load. Hold the machine in such a way that the broken pieces could not hit you in the
event of a breakage. The machine must be switched off at once if there is considerable vibration
or if damage is noticed, and after that the cause for these defects must be found.
●When working with certain materials it is possible for dust and vapours to be produced that could
create a potentially explosive atmosphere.
●The work pieces must be fixed adequately before starting work.
●Never use the machine in the vicinity of inflammable liquids or gases.
●Use suitable facilities at the workplace to keep the air clean if hazardous or explosive dusts,
vapours or aerosols are produced.
●The machine tool can still run on after it has been switched off. Put the grinder down in a safe
place and wait for it to stop without applying any pressure to the surface.
●As a matter of principle, use eye protection (EN 166 level B) and ear protection (EN
352). Wear gloves (EN 388 category 2) and protective clothing.
●Depending on the materials being worked with, personal protective equipment and dust
extraction must be provided.
●Do not wear loose-fitting clothing or jewelry. They could be caught up by moving parts. Wear a
hair net if you have long hair.
●Pay attention to the markings, restrictions on use and special notes on use on the abrasive
wheel and the grinder.
●Use a suitable abrasive wheel. An unsuitable product can create excessive amounts of grinding
particles, dust, vibration and noise.
●Only use abrasive wheels that meet the highest safety standards. These products carry the
relevant number of the EN standard and/or the "oSa" marking.
●Do not exceed the maximum pressure. Use a pressure regulator so the pressure is controlled
before it reaches the machine.

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●Abrasive wheels should be stored in such a way that they are not exposed to the harmful effects
of moisture, frost and large temperature variations or mechanical damage.
●Abrasive wheels on substrates should be stored at 18-22°C and 45-65% relative humidity.
●Abrasive belts should be stored on a rod or hook of at least 50 mm in diameter.
●Never use abrasive wheels that have passed their specified "use by" date.
●Do not change the grinder and the abrasive wheels after delivery. Never use force when
attaching them.
●Ensure that suitable chucking flanges are used and that these are in a good mechanical state
and free of foreign bodies such as grinding swarf.
●Only grind with the area of the abrasive wheel intended for that purpose. Avoid grinding with the
edges of abrasive belts, use the middle of the belt if at all possible.
●Abrasive belts that are not being used should be not be kept under tension.
●Avoid blocking and uneven wear to ensure efficient use of the abrasive wheel. If necessary,
dress it regularly.
●Check the grinder each time before use by making a visual inspection to ensure that it is
undamaged and suitable for the intended task.
●Only users with the relevant technical knowledge who have been trained by authorised
technicians who are aware of their responsibility may use the grinder.
●Use a respiratory protection mask (EN 149) if the work produces dust. The inhalation of grinding
dust can lead to lung damage.
●Disassembling or assembling our LUKAS grinder may only be done by us or an authorized
technician.
●Pay attention to flailing compressed air hoses - risk of injury.
●Use only the lubricants recommended by LUKAS.
●Take action at once if you feel tingling, stabbing pains or numbness after using the grinder for
ten minutes without a break. Avoid using the grinder continuously.
●Since vibration is felt more strongly under colder conditions, it is advisable to keep your hands
warm and to regularly move your hands and fingers.
●Keep the fastening flanges and abrasive wheels in good mechanical order and replace them if
they are worn or deformed.
●Do not hold the work piece or the machine too tightly in use and do not exert excessive pressure
on the abrasive wheel.
●Worn or defective abrasive wheels must be disposed of according to the relevant national or
international regulations.
●Bear in mind that the abrasive wheels can be contaminated by the grinding process or grinding
swarf.

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●Abrasive wheels that have been disposed must be destroyed to prevent them from being
reused.
●If they are provided, use spacers between the abrasive wheel and the chucking flange.
●Do not do the clamping device up too tightly.
●Never remove the guards of the machines and ensure that they are in good condition and
applied properly.
●Only start the machine when there is no contact between the work piece and the abrasive wheel.
●Avoid mechanical damage to the abrasive wheel due to the application of force or impacts or
heating up.
1.3 Obligations of the owner operator
The owner operator is required to ensure that the people who work with the machine
●are familiar with the underlying regulations on safety at work and accident prevention and have
been instructed in the handling of the machine,
●who have read and understood the safety and warning information in these operation
instructions and in all other documentation associated with the machine,
●are checked at regular intervals regarding safe ways of working.
Have servicing, maintenance and commissioning work done by a trained technician. Any defects
that could affect safety must be dealt with at once.

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1.4 Obligations of the personnel
All persons working with the machine are always required to
●comply with the underlying regulations for safety at work and accident prevention,
●to read and comply with the safety and warning information given in these operation instructions.
1.5 Warranty and liability
If nothing is explicitly stated to the contrary, our "General Terms and Conditions of Sales and
Delivery" shall apply. Warranty and liability claims arising from injury to persons or damage to assets
are hereby excluded if they are due to one or more of the following causes;
●Inappropriate use of the machine
●Incorrect assembly, starting up, operation and maintenance of the machine
●Operation of the machine with defective safety devices or incorrectly applied or non-functional
safety and protective devices.
●Failure to comply with the information given in the operation instructions regarding transport,
storage, assembly, commissioning, operation, maintenance and equipping of the machine
●Making constructional changes or adjustments to the machine that go beyond its normal
intended purpose
●Inadequate monitoring of parts that are subject to wear
●Repairs, inspections or maintenance work that are carried out incorrectly
●Catastrophic failures due to foreign bodies and instances of force majeure.
1.6 Explanation of the symbols
The ope
ration instructions must have been read before starting work and
are to be followed exactly in use.
DANGER
Warning of direct danger to people. Failure to comply can result in severe
or even fatal injuries.

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Lubricants, coolants and cleaners that are a hazard to the environment must be
disposed of safely!
NOTE
Important or additional information on the machine or the documentation.
Eye protection must be used or safety glasses must be worn.
Ear protection must be worn.
Warning of hand injuries.
Warning: Keep your hands away from places that have this warning sign!
There is a danger that your hands could be crushed, drawn in or otherwise injured.
ESD-protected area
The component can be destroyed by an electrostatic discharge.
Only have maintenance and repair work done on hydraulic, electrical and
pneumatic equipment by suitably trained persons and disconnect the electrical
machines from the power source!
Depressurize the hydraulic and pneumatic equipment of the machine before
carrying out any maintenance or repair work!
Change the hoses at regular intervals as part of preventive servicing, even if no
damage is visible! (Follow the details of the manufacturer.)
Used oil

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Before starting up after maintenance or repair work
●check that all screw connections have been done up tightly
●and ensure that any tank covers, screens or filters have been put back in
place
Ensure after finishing the maintenance or repair work and before starting
production again that
●all the materials, tools and other equipment that was required for the
maintenance or repair work has been removed from the working area of the
machine.
●any liquids that may have escaped have been removed
●all the safety devices of the machine function properly.
1.7 Complying with the environmental protection regulations
Comply with the legal requirements for avoiding waste and proper
recycling/disposal in all work on the machine.
Especially when carrying out installation, maintenance and repair work,
substances that are a hazard to water such as
●greases and oils
●hydraulic oils
●coolants
●cleaners containing solvents
do not pollute the ground or get into the sewer system. These substances must be
stored, transported, collected and disposed of in suitable containers.
2 Intended Use
Grinders for abrasive wheels are used to machine metals, for example, for deburring, smoothing
down weld seams or to machine cast parts.
3 Installation
●Blow out the compressed air line and hose before connecting the machine.
●Ensure that all the lines have sufficiently large cross-sections (see section Technical Data) and
that the lines are not kinked or pinched. The compressed air hoses should only be longer than 3
m in exceptional cases.

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●This LUKAS angle grinder must be operated with oil-free compressed air (see section
Maintenance and Servicing).
●Connect the grinder for use with unoiled air to a filter regulator consisting of a filter with water
separator and pressure regulator as follows:
Air consumption Connection thread
0.05 - 0.5 m
3
/min G 1/4
0.15 - 0.9 m
3
/min G 3/8
0.5 - 1.5 m
3
/min G 1/2
0.8 - 6.0 m
3
/min G 3/4
●Check the flow pressure at the take-off point. The flow pressure must be set to 6.3 bar with the
pressure regulator. A higher flow pressure leads to increased wear. If the pressure is too low the
performance is reduced.
Regarding the quality of the compressed air as per ISO 8573-1, we recommend:
CLASS RESIDUALOIL RESIDUAL DUST RESIDUAL WATER
mg/m3
Particle size
µm
max.
concentration
mg/m3
Pressure
condensation
point °C
max.
concentration
g/m3
4 5 15 8 +3 6
4 Starting Up
Ensure that the machine spindle is shorter than the inside thread of the abrasive wheel.
If the abrasive wheel comes away it can cause injuries. Check that the
abrasive wheel has been correctly and securely attached before starting up.
Only use approved abrasive wheels. Check whether the permissible rotating
speed of the abrasive wheel is greater than that of the grinder.

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Only use approved reducers or adapters for abrasive wheels that have a mounting hole that is too
large if such have not been provided by the manufacturer. If reducers are used, ensure that the
chucking flange clamps properly.
4.1 Changing the abrasive wheel
Bring the machine into the following position to change the abrasive wheel:
RIGHT WRONG
●Press the pusher at the angle head and hold it down during the entire operation.
Pusher

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INFORMATION
If the pusher has been pressed correctly the abrasive wheel cannot be turned any
longer.
●Unscrew the abrasive wheel with the supplied face spanner 828832 and replace the abrasive
wheel.
●Attach the new abrasive wheel and then release the pusher.
4.2 Adjusting the guard
Bring the machine into the following position to adjust the guard:
RIGHT WRONG
●Press the pusher at the angle head and hold it down during the entire operation.
INFORMATION
If the pusher has been pressed correctly the abrasive wheel cannot be turned any
longer.
●Bring the guard into the desired position, release the pusher and turn the guard until it audibly
clicks into place.

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4.3 Changing to left-handed operation
When the machine is supplied the handle is mounted in such a way that the angle grinder can be
used by a right-handed person.
It is possible to change it over to left-handed operation as follows:
1. Unscrew the handle 315222 (right-hand thread).
2. Unscrew the lock screw 310006 (right-hand thread) and the bushing 310000 (SW 13,
right-hand thread). Tighten up again the parts on the opposite side.
3. Unscrew the 2 countersunk screws 801221 (right-hand thread, Allen socket SW 2,5) and
remove the support 315194.
4. Turn the slide / vane 315195 into the correct position as shown in the illustration.
5. Install the support 315194 on the slide / vane (ensure that the position is correct!) and attach
the support with the 2 countersunk screws 801221.
6. Install the handle 315222 and screw it up tight when in the desired position (turn screw
3100021 into the desired position).
Pusher
Guard

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Location of the slide / vane for RIGHT-HANDED OPERATION
Location of the support for
right-handed operation
Location of the slide / vane for LEFT -HANDED OPERATION
Location of the support for
left-handed operation
5 Handling
Only use the machine with due regard to the safety instructions and maintenance stipulations.
The machine is started by the lever valve.
Slide / vane
Handle
Slide /
vane
Handle

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6 Disassembly – Assembly
Disassembly: (see the spare parts drawing)
Caution
The machine can cause hand and finger in
juries when it starts up.
Disconnect the machine from the compressed air supply before
disassembling it!
Only suitably knowledgeable employees should assemble or disassemble
it.
Check compliance with the technical data before carrying out any maintenance work!
In principle, only use original spare parts from LUKAS. Otherwise there is the danger that the
performance of the machine falls off and more maintenance is required. If you install spare parts
from other makers, the machine manufacturer is entitled to declare all his obligations under warranty
as null and void.
When disassembling the angle grinder this should be done in the reverse order to that given above:
1. Undo the 4 cylinder head screws 800465 (right-hand thread).
2. Completely remove the valve lever 315162 B.
3. Undo the tension nut 315189 with the face spanner 828832 (right-hand thread) and remove
the chucking flange 315188.
4. Press the pusher at the angle head and pull the locking pin 3151821 out of the angle head
housing.
5. Remove the guard 315191.
Warning
Lay the machine down on the work surface with the spindle side upwards before
you remove the threaded pin 315218, otherwise oil will leak out!
6. Remove the threaded pin 315218 (right-hand thread).
7. Remove the 4 cylinder head bolts 801189 from the flange 3151901 (right-hand thread) and
pull the flange and the spindle 315095, etc. out of the housing 3150965.
8. Suck out the oil (as described in section Oil Change).
9. Press the gearing, the motor and the regulator completely out of the spindle side of the angle
head towards the air inlet side of the angle head.

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Warning
Further disassembly work required a trained technician (participation in LUKAS
training) and special tools (see Accessories to Special Order).
Otherwise damage to the machine is unavoidable!
Assembly:
Warning
Check before assembling whether the outer O-rings are in good condition.
Otherwise the machine will leak and gearing oil will run out. This will lead to a total
failure of the machine!
1. Install the motor, the gearing and the regulator complete in the angle head housing.
2. Install the split washer 832070 at the motor.
3. Install the lever valve 315162 B complete with the pressure spring 315150 and the ring
315148 at the angle head.
Warning
The cylinder p
in 801357 in the motor must go into the locking hole in the lever valve
- anti-twist lock (see also Fig. Cross-section on the next page)!
The 2 threaded pins 800327 in the regulator must be aligned radially outwards.
Otherwise the machine does not start and must be sent in!
Cylinder pin
801357
Locking hole lever
valve
2x Threaded pin 800327

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Fig.: Cross-section (view from above)
4. Fasten the 4 cylinder head screws 800465 (right-hand thread).
Warning
Lay the machine down on the work surface with the spindle side upwards
before
you fill it with the oil!
5. Fill it up with oil (as described in section Oil Change).
6. Install the spindle 315095, the flange 3151901, etc. in the angle head housing and attach the
flange with the 4 cylinder head screws 801189 (right-hand thread).
7. Do up the threaded pin 315218 (right-hand thread).
8. Place the guard on the housing, press the pusher (if necessary, turn it a little to the left or
right) and install the locking pin 3151821.
IMPORTANT
Pay attention to the correct loc
ation of the groove and the locking pin 3151821 (see
Fig. Location of the groove when the pusher is pressed).
If the locking pin 3151821 has been installed correctly, it is drawn inwards when the
pusher is released.
Head side Lever side

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Fig.: Location of the groove when the pusher is pressed (locking device 315179 A)
9. Tighten up the chucking flange 315188 and the tension nut 315189 with the face spanner
828832 (right-hand thread).
Make a test run (see section Safety instructions for grinders) and check for compliance with the
technical data!
Location of the groove
for the locking pin
3151821

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6.1 Spare parts drawing
315193 E WINKELSCHLEIFMASCHINE / ANGLE GRINDER
1 x315197 C
WINKELKOPF
ANGLE HEAD
1x807721
RUNDDICHTRING
O
-RING
4x2
1x315218
GEWINDESTIF
T
THREADED PIN
1x 315177 E
MOTOR MX
AIR MOTOR MX
1 x 3151421
SCHALTER
SWITCH
1x315150
DRUCKFEDER
PRESSURE SPRING
1 x 832070
FEDERRING
SPLIT WASHER
1 x 315162 B
HEBELVENTIL
LEVER VALVE
4x 800465
ZYLINDERSCHRAUBE
CYLINDER HEAD SCREW
1x315176 B
REGLER
REGULATOR
1x315148
RING
RING
1x315178 H
GETRIEBE
GEARING
1x
315191
SCHUTZHAUBE
GUARD
1 x 315189
SPANNMUTTER
TENSION NUT
1x315188
SPANNFLANSCH
CHUCKING FLANGE
1 x 315179 A
ARRETIERUNG
LOCKING DEVICE

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1x315194
AUFLAGE
SUPPORT
2x 801221
SENKSCHRAUBE
COUNTERSUNK SCREW 1 x 310006
VERSCHLUβSCHRAUBE
LOCK
SCREW
1 x 315195
SCHIEBER
SLIDE / VANE
1 x 315200
BUCHSE
BUSHING 1x3151821
ARRETIERSTIFT
LOCKING PIN
1x315219
SCHEIBE
DISC
1x832203
NADELLAGER
NEEDLE BEARING
1x315117
VERSCHRAUBUNG
THREADED FITTING
1 x 801952
SCHRÄGKUGELLAGER
ANGULAR ROTARY JOINT
2x 823274
ZYLINDERROLLE
CYLINDER ROLL
1 x 315095
SPINDEL
SPINDLE
2x 823220
D1CHTRING
SEAL RING
1 x 824792
RUNDDICHTRING
O-RING
32,7x1.3 Viton
1 x 3151901
FLANSCH
FLANGE
4 x 801189
ZYLINDERSCHRAUBE
CYLINDER HEAD SCREW
1x 3150965
GEHÄUSE
HOUSING
1 x 802697
SCHEIBENMAGNET
DISC MAGNET
1 x 802396
LAGERNADEL
BEARING NEEDLE
2,5x12,8 rostfrei
1 x 310000
BUCHSE
BUSHING
1 x 310001
GELENK
JOINT
1 x 3100021
SCHEIBE
DISC
1 x 315222
HANDGRIFF
HANDLE
1 x 315192
ZENTRIERRING
CENTERING RING
315197 C
WINKELKOPF / ANGLE HEAD