Sealey Bg200xl User manual

1.1. ELECTRICAL SAFETY.  WARNING! It is the user’s responsibility to read, understand and comply with the following:

You must check all electrical equipment and appliances to ensure they are safe before using. You must inspect power supply leads,

plugs and all electrical connections for wear and damage. You must ensure the risk of electric shock is minimised by the installation of

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

also recommend that an RCD (Residual Current Device) is used with all electrical products. It is particularly important to use an RCD

with portable products that are plugged into an electrical supply not protected by an RCCB. If in 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 all portable electrical appliances, if used on business premises, to be 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 the appliance

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

1.1.3. Ensure the insulation on all cables and the product itself is safe before connecting to the mains power

supply. See 1.1.1. & 1.1.2. above and use a Portable Appliance Tester (PAT).

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

1.1.5. Regularly inspect power supply, leads, plugs for wear and damage and all electrical connections to ensure that none is loose.

1.1.6. Important: Ensure the voltage marked on the product is the same as the electrical power

supply to be used and check that plugs are fitted with the correct capacity fuse. A 13A

plug may require a fuse smaller than 13A for certain products.

1.1.7. DO NOT pull or carry the powered appliance by its power supply lead.

1.1.8. DO NOT pull power plugs from sockets by the power cable.

1.1.9. DO NOT use worn or damaged leads, plugs or connections. Immediately replace or have

repaired by a qualified electrician. A U.K. 3 pin plug with ASTA/BS approval is fitted. In case

of damage, cut off and fit a new plug according to the following instructions (discard old

plug safely). (UK only - see diagram at right).

Ensure the unit is correctly earthed via a three-pin plug.

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

b) Connect the BROWN live wire to 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 external insulation extends beyond the cable restraint

and that the restraint is tight.

Double insulated products are often fitted with live (BROWN) and neutral (BLUE) wires only.

Double insulated products are always marked with this symbol .

To re-wire, connect

the brown & blue wires as indicated above. DO NOT connect the brown or blue to the

earth terminal.

1.1.10. Some products require more than a 13 amp electrical supply. In such a case, NO plug will be fitted. You must contact a qualified

electrician to ensure a 30 amp fused supply is available. We recommend you discuss the installation of a industrial round pin plug and

socket with your electrician.

1.1.11. Cable extension reels. When a cable extension reel is used it should be fully unwound before connection. A cable reel with an RCD

fitted is recommended since any product which is plugged into the cable reel will be protected. The section of the cable on the cable

reel is important. It should be at least 1.5mm² but to be absolutely sure that the capacity of the cable reel is suitable for this product

and for others that may be used in the other output sockets, we recommend the use of 2.5mm² section cable.

INSTRUCTIONS FOR:

BENCH GRINDER 200MM 560W

MODEL No: BG200XL

The use of symbols in this document is to attract your attention to possible danger. The symbols and warnings themselves do not eliminate any danger, nor are they substitutes for proper

accident prevention measures.

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.

1. SAFETY INSTRUCTIONS

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

USE THE 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. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.

1.2 GENERAL SAFETY

 WARNING! Disconnect the grinder from the mains power, and ensure the grinding wheels are at a standstill before attempting to change

accessories, service or perform any maintenance.

Note: With the exception of “Abrasive Wheels Regulations”’ safety instructions will also apply to operating with a wire brush.

 Maintain the grinder in good condition and check moving parts alignment regularly.

Replace or repair damaged parts. Use recommended parts only. Non-authorised parts may be dangerous and will invalidate the warranty.

 DANGER! DO NOT use a damaged stone as it is dangerous and may cause damage or serious personal injury.

 WARNING! Only persons qualified under the “Abrasive Wheels Regulations” and holding a current grinding wheel

certificate are to change or dress grinding stones. Unplug grinder from mains power and refer to chapter 4 “Grinding Stones”

for details.

WARNING! Keep all guards and holding screws in place, tight and in good working order. Check regularly for damaged parts.

A guard or any other part that is damaged should be repaired or replaced before tool is used. The safety guard is a mandatory fitting

where grinder is used in premises covered by the Health & Safety at Work Act.

Locate grinder in an adequate working area for its function, keep area clean, tidy and free from unrelated materials. Ensure adequate

lighting.

Before each use check grinding wheel for condition. If worn or damaged replace immediately.

WARNING! Always wear approved eye or face protection when operating the grinder.

Use breathing protection in accordance with COSHH regulations if fumes or dust pose a hazard. Wear ear defenders and gloves if

necessary.

Original Language Version BG200XL Issue: 5(L)- 04/03/14

Recommended Fuse

Rating: 3A

Unpack the product and check contents against the listed below together with figs 1. & 2.

Should there be any damaged or missing parts contact your supplier immediately.

1. Eye shield with support bracket x 2 (with 2 securing screws and washers)

2. Tool rest x 2

3. Tool rest bolt, washer, knob x 2

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

Note: Eye shield clamp, bracket, and tool rest are each marked with “R” for right hand side

fixing, “L” for left.

3.1. Eye Shield.

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

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

3.1.3. Fix eye shield 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: your model may already have the tool rests attached.

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 and then read chapter 4 (grinding stones) before use.

2. INTRODUCTION & SPECIFICATIONS

The BG200XL is fitted with stone guards, adjustable eye shields and spark arrestors, an induction motor for general grinding and sharpening

operations and fine and coarse grade grinding stones. Narrow wire wheels may also be obtained for use with this machine. Contact your

Sealey dealer for details.

Motor ............................... 560W

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

Axle Diameter.........................16mm

No Load Speed .....................3000rpm

3. ASSEMBLY & INSTALLATION

fig 1

fig 2 fig 3 fig 4 fig 5

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

Stone Size ................... 8” (16mm bore)

Weight ...............................18kg

Keep hands and body clear of the workpiece when operating the grinder.

 Maintain correct balance and footing. Ensure the floor is not slippery and wear non slip shoes.

Remove ill fitting clothing. Remove ties, watches, rings, and other loose jewellery, and contain and/ or tie back long hair.

Keep children and unauthorised persons away from the working area.

 DO NOT force the grinder to achieve a task it was not designed to perform.

 DO NOT operate the grinder if any parts are damaged or missing as this may cause failure and/or personal injury.

WARNING! DO NOT grind, or sand any materials containing asbestos.

 DO NOT switch the grinder on whilst the wheel is in contact with the work piece.

 DO NOT get the grinder wet or use in damp or wet locations or areas where there is condensation.

 DO NOT use grinder where there are flammable liquids, solids or gases such as paint solvents, including waste wiping or cleaning rags etc.

 DO NOT touch the workpiece close to the ground surface as it will be very hot. Allow to cool. The workpiece may also be very sharp.

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

 DO NOT leave the grinder operating whilst unattended.

When not in use switch the grinder off, disconnect from the mains power supply and clean the machine and work area.

Original Language VersionOriginal Language Version BG200XL Issue: 5(L)- 04/03/14

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 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 & dress grinding

stones (wheels).

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

Ensure the maximum speed specification of the cutting stone is the same as, or higher than, that indicated on the machine data plate.

Check grinding stones are secure and are not worn or damaged, that there are no fissures 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 stone to break. DO NOT over tighten a stone. Never tamper with a stone in order to adapt it to 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.

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.

4.2.3. Remove the screws from the side of the wheel cover and remove the cover.

4.2.4. Hold grinding stone firmly. To protect your hands use cloth or wear gloves. Unscrew retaining nut (fig 6.1).

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 6.2), 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 stone 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 flange on 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.

 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 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 is preferred

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 reminder: 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 read, understand and apply the Safety Instructions.

Plug grinder into the mains power supply.

Place the eye shield in its appropriate safety location.

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

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 stones wear, adjust the positions of the tool rests. The rests must set at a maximum of 2mm from the stone surfaces.

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

6.3. The machine motor and bearings 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

4. GRINDING STONES

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.