Alpha Tool.Com.HK Limited Grinder HSG125 User Manual

							103 Bauer Drive, Oakland, NJ 07436 • 800-648-7229 • Fax: 800-286-0114
www.alpha-tools.com
Part No: HSG-125
      HSG-225
Alpha
®
 High-Speed
Angle Grinder
Instruction Manual
MANUAL 
						

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TABLE OF CONTENTS
High-Speed Angle Grinder Overview ...........................................................................3
 Specifi cations ....................................................................................................3
 Accessories .......................................................................................................4
 Components ......................................................................................................4
Introduction ..................................................................................................................5
 About The Symbols ...........................................................................................5
  General Safety Rules ........................................................................................6
 Work Area .........................................................................................................6
 Electrical Safety ................................................................................................6
 Personal Safety .................................................................................................6
 Service ..............................................................................................................7
  Specifi c Safety Rules ........................................................................................8
  Use Proper Extension Cords ............................................................................8
Additional Precautions For Using The High-Speed Angle Grinder ..............................9
 Safety Advice ....................................................................................................9
 How To Grind ..................................................................................................10
  How To Handle The Grinder ............................................................................10
High-Speed Angle Grinder Operation ........................................................................ 11
 Main Connection ............................................................................................. 11
  Switching On And Off ...................................................................................... 11
Before Use .................................................................................................................12
  About Double Insulation ..................................................................................13
  Laws and Regulations Of Noise Levels ..........................................................13
Using The Tool  ..........................................................................................................14
  Protective Cover Installation ...........................................................................14
 Assembling Spindle Attachments ....................................................................15
 Disassembling Spindle Attachments ...............................................................16
Checking and Replacing The Carbon Brushes .........................................................17
  Rear Cover Removal ......................................................................................17
  Carbon Brush Holder Removal .......................................................................18
  Carbon Brush Removal ...................................................................................19
 Cleaning The Commutator ..............................................................................20
 Installing The Carbon Brushes ........................................................................20
Angle Grinder Schematic (HSG-125) ........................................................................21
Angle Grinder Parts List (HSG-125) ..........................................................................22
Services and Warranty Information ...........................................................................24
Loaner Program .........................................................................................................24
Need More Information  .............................................................................................24
Warranty ....................................................................................................................24
Alpha
® Tool Repair Service ........................................................................................25
EC Declaration Of Conformity ...................................................................................26 
						

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HIGH-SPEED ANGLE GRINDER OVERVIEW
  SPECIFICATIONS
Power Supply ........................................................... Single-Phase AC, 50 / 60 Hz
Rating ............................................................................................ 115 / 230 Volts
Amperage ............................................................................................ 7.2A  /  3.6A
Power ........................................................................................................... 800W
No-load Speed ..................................................................................... 9,700 RPM
Max Disc Size ......................................................................................5” / 125mm
Arbor ............................................................................................. 5/8”-11 / M14-2
Weight .......................................................................................... 3.52 lbs / 1.6 kg
Cord ...............................................................................8.2ft / 2.5m Single Phase
                                             
Figure-1
Protection Guard
w/ Clamp Screw Spindle 
Locking Pin
Power SwitchDirection of
Rotation Arrow
Side Handle
Inside Flange Locking Flange 
						

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 ACCESSORIES
COMPONENTS:
Protective Cover w/ Clamp Screw (Part No. 130653)
Side Handle (Part No. 130433)
Inside Flange and Locking Flange Set with 7/8” Arbor (Part No. 136038 & 136039)*
Pin spanner Wrench 34 mm (Part No. 130434)
Extra Carbon Brush Set (Part No. 136046)
Extra Inside Flange & Locking Flange Set with 20mm Arbor (Part No. 136040 & 136041)**
1.
2.
3.
4.
5.
6.
Figure-2

 

 
(**Only available in the 115V) (*Available in the 115V and 230V) 
						

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INTRODUCTION
Thank you for purchasing the Alpha® High-Speed Angle Grinder.  Please read this instruc-
tion manual thoroughly to ensure safety and correct use of this tool.  Keep this manual in 
a place where operators can access it easily whenever necessary.
 ABOUT THE SYMBOLS
According to the hazard level, all safety notes in this manual are classifi ed into “DANGER”,  
“WARNING”, and “CAUTION”.
  DANGER!  Death or serious personal injury is imminent when handling this tool 
incorrectly.
  WARNING!  There is a possibility of death or serious personal injury when 
handling this tool incorrectly. 
  CAUTION!  There is a possibility of personal injury or property damage when 
handling this tool incorrectly.
NOTE:  In some situations, failing to observe WARNING notes could result in death or seri-
ous personal injury.  Be sure to read and observe the safety notes to ensure safety 
and correct use of the Angle Grinder.  
 ELECTRICAL SYMBOLS
The following show the symbols used for tool.
V     Volts
A    Amperes
W   Watts
Hz   Hertz
~ or a.c. Alternating Current
n0   No load speed
…/min  Revolution or reciprocation per minute
kg  Kilograms
mm   Millimeters
lbs   Pounds
  Protective Earth 
						

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  CAUTION!
The following are important notes for products, operation, and maintenance applicable to 
this High-Speed Angle Grinder.
GENERAL SAFETY RULES
 WORK AREA
Keep your work area clean and well lit.  Cluttered benches and dark areas invite 
accidents.
Do not operate power tools in explosive atmospheres, such as in the presence 
of fl ammable liquids, gases, or dust.  Power tools may create sparks which may 
ignite the dust or fumes.
Keep bystanders, children, and visitors away while operating a power tool. 
Distractions can cause you to lose control.
 ELECTRICAL SAFETY
Grounded tools must be plugged into an outlet properly installed and grounded 
in accordance with all codes and ordinances. Never remove the grounding prong 
or modify the plug in any way. Do not use any adaptor plugs. Check with a qualifi ed 
electrician if you are in doubt as to whether the outlet is properly grounded.  If the tools 
should electrically malfunction or break down grounding provides a low resistance path 
to carry electricity away from the user.
Avoid body contact with grounded surfaces, such as pipes, radiators, ranges, and 
refrigerators.  There is an increased risk of electric shock if your body is grounded.
Don’t expose power tools to rain or wet conditions.  Water entering a power tool 
will increase the risk of electric shock.
Do not abuse the cord.  Never use the cord to carry the tools or pull the plug from an 
outlet.  Keep cord away from heat, oil, sharp edges, or moving parts.  Replace damaged 
cords immediately.  Damaged cords increase the risk of electric shock.
When operating a power tool outside, use an outdoor extension cord marked 
“W-A” or “W”.  These cords are rated for outdoor use and reduce the risk of electric 
shock.
 PERSONAL SAFETY
Stay alert, watch what you are doing and use common sense when operating 
a power tool.  Do not use tool while tired or under the infl uence of drugs, alcohol, or 
medication.   A moment of inattention while operating power tools may result in seri-
ous personal injury.
Dress properly.  Do not wear loose clothing or jewelry.  Contain long hair.  Keep your 
hair, clothing, and gloves away from moving parts.  Loose clothes, jewelry, or long hair 
can be caught in moving parts or drawn into air vents.
Avoid accidental starting.  Be sure switch is off before plugging in.  Carrying tools with 
your fi nger on the switch or plugging in tools that have the switch on, invites accidents. •
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Remove adjusting keys or wrenches before turning the tool on.   A wrench or a 
key that is left attached to a rotating part of the tool may result in personal injury.
Do not overreach.  Keep proper footing and balance at all times.  Proper footing and 
balance enables better control of the tool in unexpected situations.  Do not use on a 
ladder or unstable support.
Use safety equipment.   Always wear eye protection.  Dust mask, nonskid safety 
shoes, hard hat, or hearing protection must be used for appropriate conditions.
 TOOL USE AND CARE
Use clamps or other practical way to secure and support the workpiece to a 
stable platform.  Holding the work by hand or against your body is unstable and may 
lead to loss of control.
Do not force tool, use the correct tool for your application.  The correct tool will do 
the job better and safer at the rate for which it is designed.
Do not use tool if switch does not turn it on or off.   Any tool that cannot be controlled 
with the switch is dangerous and must be repaired.
Disconnect the plug from power source before making any adjustments, chang-
ing accessories, or storing the tool.  Such preventive safety measures reduce the 
risk of starting the tool accidentally.
Store idle tools out of the reach of children and other untrained persons.  Tools 
are dangerous in the hands of untrained users.
Maintain tools with care.   Keep tools sharp and clean for better and safer performance. 
Follow instructions for lubricating and changing accessories.  Inspect the electrical cord 
periodically and if damaged, have it repaired by authorized service facility.  Inspect 
extension cords periodically and replace if damaged.  Keep handles dry, clean and 
free from oil and grease.
Check for damaged parts.  Before using the tool each day, a guard or other part 
that is damaged should be carefully checked to determine that it will operate properly 
and perform its intended function.  Check for alignment of moving parts, breakage of 
parts, mounting, and any other conditions that may affect its operation.  A guard or 
other part that is damaged should be properly repaired or replaced by an authorized 
service center unless otherwise indicated elsewhere in this instruction manual.  Have 
defective switches replaced by authorized service center.  Do not use the tool if it 
cannot be turned on and off by the switch.
Use only accessories that are recommended by the manufacturer for your model. 
Accessories that may be suitable for one tool, may become hazardous when used 
on another tool.
 SERVICE
Tool service must be performed only by qualifi ed repair personnel.  Service or 
maintenance performed by unqualifi ed personnel could result in a risk of injury.
When servicing a tool, use only identical replacement parts.  Follow instructions in 
the Maintenance section of this manual.  Use of unauthorized part or failure to follow 
Maintenance Instructions may create a risk of electric shock or injury. •
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 SPECIFIC SAFETY RULES
Accessories must be rated for at least the speed recommended on the tool 
warning label.  Wheels and other accessories running over rated speed can fl y apart 
and cause injury.
Hold tool by insulated gripping surfaces when performing an operation where 
the cutting tool may contact hidden wiring or its own cord.  Contact with a “live” 
wire will make exposed metal parts of the tool “live” and shock the operator.
Know your power tool.  Read operator`s manual carefully.  Learn its application and 
limitations, as well as the specifi c potential hazards related to this tool.  Following this 
rule will reduce the risk of electric shock, fi re, or serious injury.
Always wear safety glasses with side shields.  Everyday eye-glasses have only 
impact resistant lenses; they are NOT safety glasses. 
Protect your lungs.  Wear a face or dust mask if the operation is dusty. 
Protect your hearing.  Wear hearing protection during extended periods of opera-
tion. 
Inspect tool cords periodically and if damaged, have repaired at your nearest Fac-
tory Service Center or other Authorized Service Organization.  Constantly stay aware 
of cord location. 
Check damaged parts.  Before further use of the tool, a guard or other part that is 
damaged should be carefully checked to determine that it will operate properly and 
perform its intended function.  Check for alignment of moving parts, binding of moving 
parts, breakage of parts, mounting, and any other conditions that may affect its opera-
tion, A guard or other part that is damaged should be properly repaired or replaced by 
an authorized service center. 
Make sure your extension cord is in good condition.  When using an extension 
cord, be sure to use one heavy enough to carry the current your product will draw. 
An undersized cord will cause a drop in line voltage resulting in loss of power and 
overheating.
Inspect for and remove all foreign objects from workpiece before polishing.  
Follow this rule will reduce the risk of serious personal injury.
Drugs, alcohol, medication, Do not operate tool while under the infl uence  of 
drugs, alcohol, or any medication.  Follow this rule will reduce the risk of electric 
shock, fi re, or serious personal injury.
Keep hands away from polishing area.  Follow this rule will reduce the risk of cuts, 
scrapes, or serious personal injury.
Save these instruction.  Refer to them frequently and use them to instruct others who 
may use this tool.  If you loan someone this tool, loan them these instructions.
  USE PROPER EXTENSION CORDS
Use only three-wire extension cords that have three-prong grounding-type plugs and 
three-pole receptacles that accept the tool’s plug.  Make sure your extension cord is in 
good condition.  Replace or repair damaged or worn cord immediately.  When using an 
extension cord, be sure to use one heavy enough to carry the current your product will 
draw.  An undersized cord will cause a drop in line voltage resulting in loss of power and  •
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overheating.  Below table shows the correct size to use depending on cord length and 
nameplate ampere rating.  If in doubt, use the next heavier gauge.  The smaller the gauge 
number, the heavier the cord.
Ampere RatingTotal length of cord in feet (115V )
25ft 50ft 100ft 
More Than Not More Than AWG
0 6 18 16  16
6 10 18 16 14
10 12 16 16 14
12 16 14 12
Not Recommended
ADDITIONAL PRECAUTIONS FOR USING 
THE HIGH-SPEED ANGLE GRINDER
In addition to the general safety notes described on the preceding pages, please read 
and observe the following precautionary notes before using the Angle Grinder.
  DANGER!
 SAFETY ADVICE
•  Please note safety instructions on Page 3-5.
•  Do not pierce the motor housing as this could damage the double insulation.
•  Always remove plug from the outlet before making any changes to the settings or 
performing maintenance.
•  Ensure the tool is switched off prior to plugging in.
•  Keep power cable clear from working area of the machine.  The power cable should 
always lead away from you and behind the operating area.
•  Before use, check the machine, cable and plug for any damages or material fatigue. 
Only authorized service agents should perform repairs.
•  After switching off, the machine will not idle down immediately. Allow the machine to 
come to a complete stop before putting it down.
•  Always wear safety glasses and ear protection when working with this machine.  It 
is further recommended to wear safety gloves, apron, as well as sturdy non-slipping 
shoes.
•  Only use grinding discs whose permitted speed is at least as high as the highest no-
load speed of the machine.
•  Be sure wheels fi t tool properly and securely. Do not modify the tool to force fi t the 
wheel. Do not remove wheel cover. 
						

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•  Check grinding tools before use.  The grinding wheel must be properly mounted and 
turn freely.  Perform a test run for at least 30 seconds without any load.  Do not use 
damaged, out of round or vibrating grinding tools.
•  Immediately switch off the machine in case of considerable vibrations or if other 
malfunctions occur.  Check the machine in order to fi nd out the cause.
•  Always use and store the grinding wheels according to the manufacturer’s instructions. 
The fl ange bolt must be tightened before starting to work with the machine.
•  The work piece must be secured if it is not heavy enough to prevent movement.
•  Do not use emery wheel.
HOW TO GRIND
  WARNING!
1.  During operation, be sure to wear safety glasses and hearing protection.
2.  When using this grinder, some  of the dust created contains chemicals known to cause 
cancer, birth defects or other reproductive harm.  Some example of these chemicals 
are:
  a.  Lead based paints
  b.  Crystalline silica found in cement, bricks and other masonry products
  c.  Arsenic and chromium coming from pressure-treated wood
  d.  Pesticides and other chemicals that could have been applied to the work area
3.  An approved dust mask that protects the operator against these chemicals should be 
worn at all times. These dust masks are designed to fi lter out microscopic particles.
 
  DANGER!
1.  If you accidentally drop the machine, do not use until checking that the machine and 
grinding wheel are not cracked, deformed, or damaged.
2.  Grinding wheels and cutting tools used on this tool should be rated at or above the no 
load rating marked on this tool.  Running grinding wheels over their rated speeds can 
fl y apart and cause injury.
  CAUTION!
1.  Do not press the lock pin while the wheel is rotating.
2.  Do not turn the switch on with the lock pin pressed down.
 HOW TO HANDLE THE GRINDER
1.  It is not necessary to apply more force onto the machine than the force created by the 
weight of the machine itself.
2.  Applying excessive force may damage the grinding wheel and burn up the motor.  Such