Sealey Bg150xd/99 User manual

Thank you for purchasing a Sealey product. Manufactured to a high standard this product will, if used according to these instructions and

properly maintained, give you years of trouble free performance.

INSTRUCTIONS FOR:

BENCH GRINDERS

MODEL No's: BG150XD/99, BG150XW/99 & BG200/99

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS, AND

CAUTIONS. USE THIS PRODUCT CORRECTLY, AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY

CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY.

1. SAFETY INSTRUCTIONS

1.1 ELECTRICAL SAFETY

WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following:

You must check all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and

any other connectors for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of

appropriate safety devices. A Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also

recommend that a Residual Current Device (RCD) is used. It is particularly important to use an RCD with portable products that are

plugged into a supply which is not protected by an RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual

Current Device by contacting your Sealey dealer.

You must also read and understand the following instructions concerning electrical safety.

1.1.1 The Electricity at Work Act 1989 requires that all portable electrical appliances, if used on business premises, are tested by a qualified

electrician, using a Portable Appliance Tester (PAT), at least once a year.

1.1.2 The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those appliances

and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.

1.1.3 Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1 and 1.1.2

and use a Portable Appliance Tester.

1.1.4 Ensure that cables are always protected against short circuit and overload.

1.1.5 Regularly inspect power supply cables and plugs for wear or damage and check all

connections to ensure that none is loose.

1.1.6 Important: Ensure that the voltage marked on the appliance matches the power supply

to be used and that the plug is fitted with the correct fuse - see fuse rating at right.

1.1.7 DO NOT pull or carry the appliance by the power cable.

1.1.8 DO NOT pull the plug from the socket by the cable.

1.1.9 DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty

item repaired or replaced by a qualified electrician. When a BS 1363/A UK 3 pin plug is

damaged, cut the cable just above the plug and dispose of the plug safely.

Fit a new plug according to the following instructions (UK only).

a)Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.

b)Connect the BROWN live wire to the live terminal ‘L’.

c) Connect the BLUE neutral wire to the neutral terminal ‘N’.

d)After wiring, check that there are no bare wires, that all wires have been correctly connected, that the cable outer insulation extends

beyond the cable restraint and that the restraint is tight. Double insulated products, which are always marked with this symbol , are

fitted with live (brown) and neutral (blue) wires only. To rewire, connect the wires as indicated above - DO NOT connect either wire to

the earth terminal.

1.1.10 Products which require more than 13 amps are supplied without a plug. In this case you must contact a qualified electrician to ensure

that a suitably rated supply is available. We recommend that you discuss the installation of an industrial round pin plug and socket

with your electrician.

1.1.11 If an extension reel is used it should be fully unwound before connection. A reel with an RCD fitted is preferred since any appliance

plugged into it will be protected. The cable core section is important and should be at least 1.5mm², but to be absolutely sure that the

capacity of the reel is suitable for this product and for others which may be used in the other output sockets, we recommend the use

of 2.5mm² section cable.

1.2 GENERAL SAFETY

 Disconnect the grinder from the mains power before changing accessories, servicing or performing any maintenance.

 Maintain grinder and discs in good condition. Check moving parts and alignment. If necessary use an authorised service agent.

 Replace or repair damaged parts. Use genuine parts only. Unapproved parts may be dangerous and will invalidate the warranty.

WARNING! Always work with the grinder safety guard in place.

 The grinding wheel or disc must only be changed by persons holding an appropriate grinding wheel certificate.

 Wear approved safety goggles, ear defenders, appropriate dust mask if grinder generates dust and safety gloves.

 Remove ill fitting clothing. Remove ties, watches, rings, and other loose jewellery, and contain long hair.

 Use grinder in a suitable work area, keep area clean, tidy and free from unrelated materials, and ensure adequate lighting.

 Maintain correct balance and footing. DO NOT over-reach and ensure the floor is not slippery. Wear non skid shoes.

 Use only approved grinding discs, and only use the normal grinding surface. Never use the side or upper surface of disc for cutting.

 Check grinding disc to ensure they are not split, cracked or damaged in anyway. See chapter 4. If in doubt to not use the disc.

 Grinding discs must be securely attached before use, but not over tightened.

 Secure unstable workpiece with a clamp, vice or other adequate holding device, and ensure the grinder is griped with both hands.

 Keep non essential persons away from the working area, use screens if necessary.

 DO NOT operate the grinder if any parts are missing or the grinder is damaged.

 DO NOT use the grinder for a task it was not designed to perform.

 DO NOT operate grinder where there are flammable liquids or gasses.

WARNING! DO NOT grind any materials containing asbestos.

 DO NOT get the grinder wet or use in damp or wet locations.

 DO NOT switch the grinder on whilst the disc is in contact with the workpiece.

 DO NOT cover the grinder air vents. To do so will overheat the machine.

 DO NOT touch the workpiece immediately after grinding as it will be very hot.

 DO NOT use the grinder as a fixed tool, and DO NOT try to cool the grinding discs with water or other lubricants.

 DO NOT hold unsecured work in your hand, and DO NOT touch the grinding disc whilst operating, or whilst plugged into the mains power.

 DO NOT leave the grinder running unattended and DO NOT lay the grinder down whilst running.

 DO NOT operate the grinder when you are tired or under the influence of alcohol, drugs or intoxicating medication.

 When not in use switch grinder off, remove plug from power supply and store in safe, dry, childproof area.

FUSE RATING 3 AMP

Blue

Neutral

Wire

Yellow & Green

Earth Wire

Cable

Restraint

Brown

Live

Wire

Original Language Version BG150XD/99, BG150XW/99 & BG200/99 Issue: 5 - 16/08/10

4. GRINDING STONES

2. INTRODUCTION & SPECIFICATIONS

Your Bench Grinder is fitted with adjustable eyeshield and spark arrestors, as well as push/pull power switch which provides extra operational

safety. The grinder is fitted with an induction motor for general grinding, sharpening and workshop use. Models BG150XD/99 and BG200/99

are supplied with fine and coarse grade grinding stones. Model BG150XW/99 is supplied with one coarse stone and a wire brush. Narrow wire

wheels may also be obtained for use on all models, contact your Sealey dealer for details.

3. ASSEMBLY & INSTALLATION

4.1 MANDATORY SAFETY INSTRUCTIONS (The following instructions must be observed together with chapter 1 safety).

DANGER! Use of a damaged stone is dangerous and may cause damage and/or personal injury.

WARNING! Ensure grinder is unplugged from the mains power supply before attempting to change grinding stones (or wheel).

Only persons qualified under the “Abrasive Wheels Regulations” and holding a current grinding wheel certificate are authorised

to change and dress grinding stones (wheels).

Grinding stones (wheels) used with this machine must be of an adequate speed rating and suitable for the material to be ground.

Ensure the grinding stone’s maximum speed specification is higher than that indicated on the machine data plate.

Check grinding stone is secure, the stone is not worn or damaged and that there are no splits or cracks. If damaged replace immediately.

Ensure replacement stone is not damaged in any way such as cracks, deformations or splinters etc. Also check the mounting flanges

to ensure they are not deformed, burred or chipped. Damaged items must NOT be used as they may cause irregular pressure on the

stone which may cause a stone to break. DO NOT over tighten a stone. Never tamper with a stone in order to adapt it to a different size

holder.

Install a new stone as in 4.2. Once mounted on the grinder test the stone before use by facing the grinder in a safe direction (point

away from yourself, others and vulnerable items) and run for a short time. Dress the stone if necessary.

Model No: BG150XD/99 BG150XW/99 BG200/99

Motor: .........................450 Watts ...........................450 Watts ..........................600 Watts

Input:..............................230V ...............................230V ..............................230V

Axle Diameter: .....................13mm ..............................13mm .............................16mm

Loaded With: ..................2 x Stones ...............1 x Stone 1 x Wire Brush .........................2 x Stones

Stone Rating: ....................3000rpm ............................3000rpm ...........................3000rpm

Stone Size: ............. Ø150 x 20 x 13mm....................Ø150 x 20 x 13mm .................. Ø200 x 25 x 16mm

Wire Brush Bore Size: ................. n/a ..............................13mm ...............................n/a

Vibration Level:....................0.5m/s² .............................0.5m/s² ............................0.8m/s²

Unpack the product and check contents. If there are any damaged or missing parts contact your

supplier immediately.

 WARNING! Before assembly check to ensure grinder is unplugged from mains.

3.1 EYESHIELD

3.1.1 Remove retaining screws (fig 1.A) from the eyeshield bracket.

3.1.2 Position the eyeshield bracket on the underside of the stone cover and align holes (fig 2).

3.1.3 Fix eyeshield to cover with screws (fig 2.1).

If the shield is loose and drops down, tighten shield screws (fig 3.2).

3.1.4 Loosen screw (fig 3.1.) and adjust the arrestor so it is 2mm from the stone face (fig 4).

3.1.5 Securely tighten arrestor screw (fig 3.1).

3.2 TOOL REST

Note: Some models may already have the tool rest assembled, but stone clearance must still be checked.

3.2.1 Take tool rest (fig 5) and align it with bolt slot on the inside of the grinding stone cover (X).

3.2.2 Pass bolt (A) through both slots and place washers (B) onto bolt.

3.2.3 Position the rest at a maximum of 2mm from the stone surface and secure the assembly by tightening knob (C).

3.2.4 Turn the grinding stones by hand to ensure clearance of above items.

3.3. Installation. Securely bolt the grinder to a fireproof workbench using the base holes as a template. Check that all assembly nuts and

bolts are secure then read chapter 4 (grinding stones) before use.

fig 1

fig 2 fig 3 fig 4 fig 5

DANGER OF FIRE/EXPLOSION HAZARD

WARNING! The grinding process can produce streams of sparks (especially when grinding metal) which are a potential source of ignition.

DO NOT use the grinder where there are flammable liquids, solids or gases.

DO NOT allow grinder sparks to make contact with the operator’s clothing or any other fabric such as cleaning rags. Fabrics contaminated with inflammable

materials such as petrol, oil, grease, paint and solvents are a particular fire hazard.

To reduce the risk of clothing catching fire the operator should wear wool or cotton outer garments treated with a fire retardant in preference to man-made fibres.

Risk of Hand Arm Vibration Injury

Bench Grinder Models: BG150XD/99, BG150XW/99 & BG200/99 when operated in accordance with these instructions and tested in accordance with

EN 28662-2: 1994 results in the following vibration emissions declared in accordance with BS EN12096: 1996.

Measured vibration emission value: BG150XD/99 & BG150XW/99...0.5m/s², BG200/99... 0.8m/s²

Uncertainty: BG150XD/99 & BG150XW/99...0.2m/s², BG200/99... 0.3m/s²

These values are suitable for comparison with emission levels of other tools that have been subject to the same test. This tool may cause hand-arm

vibration syndrome if its use is inadequately managed. Recommended Measures to reduce risk of hand-arm vibration syndrome:

This item represents a low Hand Arm Vibration risk to users. The calculated minimum usage period exceeds 8 hours. We recommend appropriate safety

equipment is utilised and regular breaks for the operator are employed to reduce any residual risk of fatigue or repetitive strain injury.

Original Language Version BG150XD/99, BG150XW/99 & BG200/99 Issue: 5 - 16/08/10

4.2 STONE CHANGING PROCEDURE

WARNING! Unplug grinder from the mains power supply before changing stone.

4.2.1 Raise the eye shield up, and away from the stone.

4.2.2 Loosen and pull the tool rest out as far as possible, but, DO NOT remove (fig 6).

4.2.3 Remove the screws from the side of the wheel cover and remove the cover (fig 6).

4.2.4 Hold grinding stone firmly. To protect your hands use cloth or wear gloves. Unscrew retaining nut (fig 7.1.).

Note: The nut on the right side of the grinder has standard right hand thread (undo anti-clockwise). The left

side nut has a left hand thread and must be loosened by turning clockwise. It may be necessary to strike

the wrench sharply in the loosening direction with the heel of your hand to loosen the nut.

4.2.5 Remove grinding stone washer (fig 7.2), blotter (3), stone (4), 2nd blotter (5), washer (6) from main spindle (7).

4.2.6 Carefully inspect the new stone before installing to ensure there are no fissures, chips, or cracks.

WARNING! DO NOT USE A DAMAGED STONE.

4.2.7 Inspect the blotters, if they are damaged replace them. The grinder must never be used without

blotters. Should you not have any available when you need to replace them, cut out a piece of

suitable cardboard the same shape for temporary use only.

4.2.8 Install the new stone by reversing steps above. Ensure washers (2 & 6) are installed with the

flangeon the outside, (i.e. the concave side against the blotter).

4.2.9 Hold stone steady and secure locking nut. DO NOT over tighten as this may crack the stone.

4.2.10 Replace stone cover, re-adjust tool rest to a maximum of 2mm from stone face and tighten

securely.

Note: You do not require a certificate to change a wire wheel. Assembly is the same as with a stone.

5.1 PRE-USE INSPECTION

Note: Use the same clearance and alignment information if your model has a wire brush.

 WARNING! INSPECT THE GRINDER BEFORE OPERATING THE MACHINE. ENSURE THE GRINDER IS UNPLUGGED FROM

THE MAINS POWER BEFORE COMMENCING THE INSPECTION.

5.1.1 Check the tool rests are securely fixed and are set at a maximum of 2mm from the grinding stone.

5.1.2 Check that eye shields are in good condition, are secure and that you can see through them clearly.

5.1.3 Turn the grinding stones by hand and check for any damage. Check they do not touch the tool rests and are correctly aligned.

If any of the above checks fail, replace, repair, or adjust as necessary before starting the grinder.

5.2 STONE USE

Depending on the model, grinders are supplied with one or two aluminous oxide stones. Stones have two grades, fine for hard

materials and coarse for soft materials.

When grinding, should surface of the stone become “loaded” (coated with particles of the material being ground) it is probably the

wrong grade of stone for the job.

IMPORTANT: Grinding stones MUST ONLY be assembled by a person holding a grinding wheel certificate. See chapter 4.

5.3 USING THE GRINDER

 WARNING! Before commencing work, ensure you have read, understood, and apply the chapter 1. Safety Instructions

5.3.1 Plug grinder into the mains power supply.

5.3.2 Place the eyeshield in its appropriate safety location.

5.3.3 Switch the grinder on and bring the workpiece slowly into contact with the spinning stone, or wire wheel.

5.3.4 When you have completed your task, unplug the grinder from the mains power supply, and clean the machine ready for next use.

6. MAINTENANCE

 WARNING! Ensure the grinder is unplugged from the mains power supply before performing any maintenance or service.

6.1 As the grinding stone wears, adjust the position of the tool rests. The rest must be set at a maximum of 2mm from the stone surface.

6.2 Regularly remove the grinding stone covers and clean out any dust and dirt.

6.3 The machine motor and bearing are sealed units and require no regular maintenance. Should you require assistance, contact your

local Sealey service agent.

6.4 For information relating to the handling and maintenance of grinding stones refer to chapter 4.

5. OPERATING INSTRUCTIONS

fig 6

fig 7

NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.