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INSTRUCTION MANUAL
150mm (6") 1/2HP / 200mm (8") 3/4HP
Bench Grinders
• Melbourne • Perth • Auckland • Hong Kong • Shanghai
• Taipei • New York • Verona • London • Paris
BG612HPL
BG834HPL
031222 ED7 DR
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Contents
Warranty 2
Introduction 3
Environmental protection 3
Description of symbols 3
Specifications 3
Safety instructions 4
Additional safety rules for bench grinders 6
Unpacking 6
Connecting to the power supply 6
Know your product 7
Fitting and adjusting the eye shields 8
Fitting and adjusting the spark deflectors 8
Fitting the tool rests 8
Bench mounting the grinder 9
Using the on/off switch 9
Using the work light 9
Operation 10
Changing a grinding wheel 10
Fitting a wire wheel 11
How to true and dress the wheels 11
Grinder adjustments 11
Maintenance 11
Lubrication 11
Cleaning 12
General inspection 12
Repairs 12
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Full 2 Years Home Use Warranty
Whilst every effort is made to ensure your complete
satisfaction with this tool, occasionally, due to the mass
manufacturing techniques, a tool may not live up to our
required level of performance and you may need the
assistance of our service department.
This product is warranted for a 2-year period for home
domestic use from the date of the original purchase. If
found to be defective in materials or workmanship, the
tool or the offending faulty component will be replaced
free of charge with another of the same item. A small
freight charge may apply.
The warranty replacement unit is only made available by
returning the tool to the place of purchase with a
confirmed register receipt. Proof of purchase is essential.
We reserve the right to reject any claim where the
purchase cannot be verified.
This warranty does not include damage or defects to the
tool caused by or resulting from abuse, accidents,
alterations or commercial or business use.
It also does not cover any bonus accessories unless the
tool is a GMC Platinum Professional model.
Please ensure that you store your receipt in a safe place.
Conditions apply to the above warranty.
If you need direction of what constitutes a free of
charge warranty claim, please review the guide given on
the rear of the Receipt Holder. An indication is given as
to the types of claim that are permissible, and those
that are not.
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Description of symbols
The rating plate on your tool may show symbols. These
represent important information about the product or
instructions on its use.
Wear hearing protection.
Wear eye protection.
Wear breathing protection.
Conforms to relevant standards for
electromagnetic compatibility.
Specifications
Nominal voltage: 230 – 240Vac ~ 50Hz
BG612HPL BG834HPL
HP 1/2HP 3/4HP
Watts 375W 550W
Spindle Speed 2850RPM 2850RPM
Diameter Wheel 1 150mm 200mm
Wheel 2 150mm 200mm
Width Wheel 1 25mm 25mm
Wheel 2 25mm 25mm
Grit Wheel 1 36 36
Wheel 2 60 60
Bore Size Wheel 1 12.7mm 16mm
Wheel 2 12.7mm 16mm
Work Light Yes Yes
Spindle Lock Yes Yes
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Dear Customer
If you require any help with your product, whether it
is a Warranty claim, spare part or user information,
please phone our Help Line for an immediate response.
Phone 1300 880 001 in Australia or 0800 445 721 in
New Zealand.
Introduction
Your new GMC power tool will more than satisfy your
expectations. It has been manufactured under stringent
GMC Quality Standards to meet superior performance
criteria.
You will find your new tool easy and safe to operate,
and, with proper care, it will give you many years of
dependable service.
Caution. Carefully read through this entire Instruction
Manual before using your new GMC Power Tool. Take
special care to heed the Cautions and Warnings.
Your GMC power tool has many features that will make
y
our job faster and easier. Safety, performance, and
dependability have been given top priority in the
development of this tool, making it easy to maintain
and operate.
Environmental protection
Recycle unwanted materials instead of
disposing of them as waste. All tools, hoses
and packaging should be sorted, taken to
the local recycling centre and disposed of
in an environmentally safe way.
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Safety instructions
The tool must be used only for the prescribed purpose.
Any uses other than those mentioned in this manual will
be considered a case of misuse. The user and not the
manufacturer shall be liable for any damage or injury
resulting from such cases of misuse.
To use this tool properly, you must observe the safety
regulations, the assembly instructions and the operating
instructions to be found in this Manual. All persons who
use and service the machine have to be acquainted with
this Manual and must be informed about its potential
hazards. Children and infirm people must not use this
tool. Children should be supervised at all times if they are
in the area in which the tool is being used. It is also
imperative that you observe the accident prevention
regulations in force in your area. The same applies for
general rules of occupational health and safety.
The manufacturer shall not be liable for any changes
made to the tool nor for any damage resulting from
such changes.
Warning. Before connecting a tool to a power source
(mains power point receptacle, outlet, etc.), be sure that
the voltage supply is the same as that specified on the
nameplate on the tool. A power source with a voltage
greater than that specified for the tool can result in
serious injury to the user, as well as damage to the tool.
If in doubt, do not plug in the tool. Using a power source
with a voltage less than the nameplate rating is harmful
to the motor.
Even when the tool is used as prescribed it is not possible
to eliminate all residual risk factors. The following hazards
may arise in connection with the tool’s construction
and design:
• Contact with the wheel.
• Kickback of work piece and parts of work piece.
• Wheel fracture.
• Catapulting of wheel pieces.
• Damage to hearing if effective earmuffs are not worn.
• Damage to eyes if eye protection is not worn
• Damage to lungs if breathing protection is not worn
• Always remove the plug from the mains socket before
making any adjustments or maintenance, including
changing the wheel.
Warning. When using power tools, basic safety
precautions should always be taken to reduce the risk of
fire, electric shock and personal injury. Also, please read
and heed the advice given in the additional important
safety instructions.
1. Keep the work area clean and tidy. Cluttered work
areas and benches invite accidents and injury.
2. Consider the environment in which you are working.
Do not use power tools in damp or wet locations. Keep
the work area well lit. Do not expose power tools to
rain and high humidity. Do not use power tools in the
presence of flammable liquids or gases.
3. Keep visitors away from the work area. All visitors
and onlookers, especially children and infirm persons
should be kept well away from where you are working.
Do not let others in the vicinity make contact with the
tool or extension cord.
4. Store tools safely. When not in use, tools should be
stored in a dry, high place or locked up out of reach.
5. Do not force the tool. The tool will do the job
better and safer working at the rate for which it
was designed.
6. Use the correct tool for the job. Do not force small
tools or attachments to do the job best handled by a
heavier duty tool. Never use a tool for a purpose other
than that for which it was intended.
7. Dress correctly. Do not wear loose clothing or jewelry.
They can be caught in moving parts. Rubber gloves and
non-slip footwear are recommended when working
outdoors. If you have long hair, wear a protective
hair covering.
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8. Use safety accessories. Safety glasses and earmuffs
should always be worn. A face or dust mask is
also required.
9. Do not abuse the power cord. Never pull the cord to
disconnect the tool from the power point. Keep the
cord away from heat, oil and sharp edges.
10. Secure the work piece. Use clamps or a vice to hold
the work piece. It is safer than using your hand and
frees both hands to operate the tool.
11. Do not overreach. Keep your footing secure and
balanced at all times.
12. Look after your tools. Keep tools clean and sharp for
better and safer performance. Follow the instructions
regarding lubrication and accessory changes. Inspect
tool cords periodically and, if damaged, have them
repaired by an authorised service facility. Inspect
extension cords periodically and replace them if
damaged. Keep tool handles dry, clean and free from
oil and grease.
13. Disconnect idle tools. Switch off the power and
disconnect the plug from the power point before
servicing, when changing accessories and when the
tool is not in use.
14. Remove adjusting keys and wrenches. Form the
habit of checking to see that keys and adjusting
wrenches are removed from the tool before switching
it on.
15. Avoid unintentional starting. Always check that the
switch is in the OFF position before plugging in the
tool to the power supply. Do not carry a plugged in
tool with your finger on the switch.
16. Use outdoor rated extension cords. When a tool is
used outdoors, use only extension cords that are
intended for outdoor use and are so marked.
17. Stay alert. Watch what you are doing. Use common
sense. Do not operate a power tool when you
are tired.
18. Check for damaged parts. Before using a tool, check
that there are no damaged parts. If a part is slightly
damaged, carefully determine if it will operate
properly and perform its intended function. Check for
alignment of moving parts, binding of moving parts,
breakage of parts, proper mounting and any other
conditions that may affect the operation of the tool.
A part that is damaged should be properly repaired or
replaced by an authorised service facility, unless
otherwise indicated in this Instruction Manual.
Defective switches must be replaced by an authorised
service facility. Do not use a tool if the switch does
not turn the tool on and off correctly.
19. Guard against electric shock. Prevent body contact
with grounded objects such as water pipes, radiators,
ranges and refrigerator enclosures.
20. Use only approved parts. When servicing, use only
identical replacement parts. Use an authorised service
facility to fit replacement parts.
Warning. The use of an accessory or attachment,
other than those recommended in this Instruction
Manual, may present a risk of personal injury.
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Additional safety rules for bench grinders
• Always remove the plug from the mains socket before
making any adjustments or maintenance, including
changing the wheel.
• Always wear eye protection and check that the eye
shields on the grinder are properly adjusted.
• Always turn the grinder off when it is not in use and
never leave it unattended without first switching off
and removing the power plug. Never leave the grinder
until the grinding wheels have come to a complete stop.
• Make sure that any replacement wheel is rated at
3000RPM or higher.
• Do not let anyone under 18 years operate this tool.
• Rags, cloths, cord, string and the like should never be
left around the work area.
• If you are interrupted when operating the tool,
complete the process and switch off before looking up.
• Periodically check that all nuts, bolts and other fixings
are properly tightened.
• Do not use a wheel that has received a blow, especially
to the side of the wheel.
• Replace a cracked or suspect wheel.
• Always allow a new wheel to run for a few minutes at
full speed before using it. Stand to one side at start up.
• Check that the wheel rotates freely each time before
start up.
• Do not use the grinder unless all the guards are properly
fitted and secure.
• Check that the tool rests are properly adjusted before
commencing use.
• Do not overload the grinder. Allow the grinder to run at
full speed, or close to full speed during use.
• Never apply excessive pressure to the wheel. It might
shatter causing personal injury.
• Make sure that the wheel is not in contact with the
work when you start the grinder.
• When using the grinder, use safety equipment including
safety goggles or shield, ear protection, dust mask and
protective clothing including safety gloves.
Wear goggles
Wear ear protection
Wear a breathing mask
Unpacking
Due to modern mass production techniques, it is unlikely
that your GMC Power Tool is faulty or that a part is
missing. If you find anything wrong, do not operate the
tool until the parts have been replaced or the fault has
been rectified. Failure to do so could result in serious
personal injury.
Connecting to the power supply
The GMC Bench Grinders covered in this manual are
designed to operate from a standard household supply of
230-240V AC. Prior to plugging in the tool, check the
rating label on the rear of the grinder and ensure that it
states the tool’s operating voltage is 240V.
All the grinders are of Class 1 Category (earthed) and are
fitted with a 3-core cable and plug. Should the cable or
plug be damaged, the product should be serviced by an
authorised Service Centre to avoid a hazard.
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Know your product
Before using the bench grinder, familiarise yourself with
all the operating features and safety requirements.
The GMC Bench Grinders are designed for light to
moderate duty applications in a home environment. They
are not intended for use by trade persons. They are ideal
for sharpening tools such as drill bits and chisels. The
larger tools can be applied to heavier grinding
applications on steel sections.
All the bench grinders can be fitted with a wire wheel
provided that the wheel is rated for use at 3000RPM
or higher.
1. MagniVision eye shield 8. On/Off switch
2. Eye shield 9. Light On/Off switch
3. Grinding wheel 10. Adjustable tool rest
4. Outer guard 11. Wheel guard
5. Spindle lock button 12. Spark deflector
6. Rubber Mounts 13. Work light
7. Base 14. Tool storage drawer
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3
2124 9 5
7
8
10
11
14
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Caution. During use it is important not to overload the
grinder. The grinder should run at close to full speed. If
you are applying too much pressure the grinder will start
to slow down. Under these conditions, remove the part
being ground and allow the grinder to return to full
speed. Re-apply the part to the grinder, but with a little
less force.
All of the grinders are supplied with grinding wheels
designed for metal use only. The grinding of Copper, Brass,
Aluminium, Wood or other similar materials will “clog” the
grinding wheel.
Warning. Never attempt to grind Magnesium.
Fitting and adjusting the eye shields
Important. Prior to fitting the eye shields, ensure the
grinder is turned off and the power plug is removed from
the socket.
Note. Always check to ensure the eye shields are correctly
fitted each time the grinder is used. Eye shields must be
fitted over each grinding wheel on all bench grinders in
the range.
1. The MagniVision eye shield (1) features a magnifying
glass incorporated into the design to provide greater
visibility and improved accuracy.
2. Take the MagniVision eye shield and fit it to the top of
the right hand side light assembly. The other eye shield
(2) should be installed on the left hand side.
3. Fit a plastic coated screw
through each side of the eye
shield into the pivot points on
the light assembly and
tighten firmly to the point
where the shield is secure, but
still able to be adjusted up
and down.
The securing screws are plastic
coated so they can be adjusted at any time without the
use of tools.
Fitting and adjusting the spark deflectors
1. The spark deflectors (12) are already fitted to the
bench grinder but will need to be adjusted prior to use,
and then over time to compensate for wheel wear.
2. To adjust the spark deflectors
loosen the screw using the
allen key supplied.
3. Slide the spark deflector up or
down so that the bottom edge
is less than 6mm from the
surface of the wheel, but not
touching the wheel.
4. Rotate the wheel by hand one
full rotation to ensure the
wheel can rotate without
contacting the spark deflector.
Firmly tighten the screw
retaining the spark deflector.
Fitting the tool rests
The tool rests (10) are required for each high speed
grinding wheel to assist in the grinding operation.
Caution. Never use a Bench Grinder on which the tool rest
has not been fitted or where the tool rest has not been
correctly adjusted.
The right hand side tool rest features an indentation that
helps you rest your work piece for more accurate grinding.
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Note. The tool rests are right and left handed. Follow the
diagrams to ensure the correct tool rest is fitted to the
correct side.
Important. Prior to fitting the tool rests, ensure the
grinder is turned off and the power plug is removed from
the socket.
1. Remove the lower screw on
the wheel guard (11).
2. Hold the tool rest (10) in the
correct position against the
inner surface of the wheel
guard. Fit the screw through
both sides of the guard and
then through the tool rest.
3. Fit the star washer first,
followed by the flat washer
and then the plastic coated
nut to the screw and tighten
the nut sufficiently to support
the tool rest but still allowing
the tool rest to slide inwards
and outwards.
4. Slide the tool rest to within a
maximum of 1.5mm from the wheel. Rotate the wheel
one full revolution by hand to ensure the wheel does
not contact the tool rest.
5. Tighten the thumb nut firmly to retain the assembly.
Repeat the assembly operation for the second tool rest.
Bench mounting the grinder
The GMC Bench Grinders are supplied with 4 rubber mounts
(6) which assist in reducing the transmission of vibration.
It is strongly recommended that the grinder be firmly
mounted to a bench or stand for safe operation.
The base of the grinder has a 12mm hole in each corner.
These holes accept bolts up to 10mm in diameter.
Mounting bolts are not supplied with the unit.
Where the grinder is to be mounted to a steel work bench,
it is advisable to place a piece of timber between the
bench and grinder then bolt through the grinder and
timber into the bench. This further assists to reduce
vibration.
Important. When directly mounting the grinder ensure:
• The surface under the grinder is flat and clean.
• The 4 mount bolts are applied evenly and not over
tightened.
Note. The four rubber mounts should remain in place if
mounting bolts are used.
Using the On/Off switch
1. To turn the grinder on, press the right hand side of the
On/Off switch (8) to the position marked "ON"
2. To turn the grinder off, press the left hand side of the
On/Off switch (8) to the position marked "OFF".
Using the work light
1. The work light (13) can be used to illuminate the work
area and provide greater visibility.
2. To turn the work light on press the light On/Off switch
(9) to the position marked " ON".
3. To turn the work light off press the light On/Off switch
(9) to the position marked " OFF".
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Operation
Important. Prior to using the grinder, check that the eye
shields, spark deflectors, and tool rests are fitted and
correctly adjusted and that you are wearing safety gear
including eye, hearing and breathing protection.
1. Turn the wheel by hand to make sure it does not touch
the guard, eye shields, spark deflectors or tool rests and
runs freely.
2. Stand to one side, turn the switch (8) on and allow the
motor to reach full speed.
3. Support the work piece on the tool rest (10) and
gradually feed the work piece onto the wheel. Use pliers
to hold small work pieces.
Note. Traverse the work piece across the full width of the
wheel to prolong its flat surface.
4. If the grinding operation causes the motor speed to
noticeably decrease, pull back the work piece, allow the
motor to regain full speed and restart the grinding
operation, but apply less force.
Warnings. Only use the front face of the grinding wheel,
not the sides. Note that the work piece can get very warm.
It may be necessary to cool a work piece by dipping it in a
coolant or in water. Do not apply coolant or water to the
grinding wheel.
Changing a grinding wheel
Important. Prior to changing a wheel, ensure the grinder
is turned off and the power plug is removed from the
socket. Make sure that the replacement wheel is rated at
3000RPM or higher.
1. Remove the retaining screw and
take off the tool rest (10).
2. Remove the retaining screw
and take off the spark
deflector (12).
3. Take off the third retaining
screw and remove the outer
guard (4).
4. Depress and hold the spindle
lock button and turn the wheel
by hand until it locks in place.
Remove the retaining nut (see
note below for correct direction
of rotation), outer flange and
the wheel.
Note. The wheel on the left-hand
side of the grinder has a lefthand thread and is unscrewed in a clockwise direction. The
wheel on the right-hand side of the grinder has a righthand thread and is unscrewed in
an anti-clockwise direction.
5. Fit the replacement wheel on
the shaft ensuring that there
is a blotter between the wheel
and clamp washers on each
side of the wheel, and ensure
the wheel is a slide fit (not
loose) on the spindle.
6. Replace the outer flange and retaining nut (see the
Note above regarding the direction of rotation of the
nut).
7. Depress and hold the spindle lock button and tighten
the nut. Do not over tighten.
8. Replace the outer guard.
9. Replace the retaining screw, spark deflector and tool
rest.
10. Re-adjust the tool rest and spark deflector.
11. Rotate the wheel by hand to check for free movement
and proper adjustments.
12. Plug in the grinder, put on eye protection, stand to
one side and run the grinder at full speed for several
minutes.
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Fitting a wire wheel
Your bench grinder is capable of fitting a wire wheel
instead of a grinding wheel.
When fitting a wire wheel ensure the wire wheel is the
correct size for the grinder and also ensure the bore size of
the wheel is correct for the spindle of the grinder.
Refer to the specification section of this manual for
grinding wheel and bore sizes.
When fitting the wire wheel, follow the details as
described in the section ‘Changing a grinding wheel’ on
how to remove the grinding wheel. Ensure to leave the
inner flange on the spindle of the grinder. Supplied with
the grinder are 2 small rubber washers. Fit one rubber
washer on to the spindle and push all the way until it
makes contact with the inner flange. Slide the wire wheel
onto the spindle, ensuring the wheel is a slide fit onto the
shaft, all the way to the rear flange. Then fit the second
rubber washer onto the spindle and push it against the
wire wheel. Fit the outer flange and securing nut and
tighten the nut as described in the section ‘Changing a
grinding wheel’. Assemble the grinder and test as per the
details in ‘Changing a grinding wheel’.
Warning. Ensure to wear safety glasses.
How to true and dress the wheels
Dressing a wheel cleans and levels the front surface to
increase efficiency of operation and prevent vibration.
1. Dressing a wheel involves the use of a wheel dresser
which is not supplied with the grinder. Follow the
manufacturers instructions of the wheel dresser.
2. Adjust the tool rest to allow the front part of the wheel
dresser to fit between the tool rest and wheel.
3. Start the motor and move the dresser across the front
of the wheel a sufficient number of times until the
surface is level. It is not necessary to apply excessive
force in an attempt to dress the wheel in one pass of
the wheel dresser.
4. Adjust the tool rest so that it is no more than 1-1.5mm
from the wheel.
5. Adjust the spark deflector to ensure the gap between
the bracket and wheels is less than 6mm.
Grinder adjustments
During the life of the grinder some adjustments are
required to maintain a safe working environment. Please
ensure the following:
• Always adjust the eye shields to the most
comfortable and most effective angle to suit the task
being performed.
• As the wheels wear, the spark deflector must be adjusted
to ensure the gap between the spark deflector and the
wheel does not exceed 6mm.
• As the wheels wear the tool rests must also be adjusted
so there is never a gap greater than 1.5mm between the
wheel and the edge of the tool rest.
Maintenance
Prior to any maintenance ensure the power has been
turned off and the plug is removed so that the grinder is
fully disconnected from the 240V supply.
Lubrication
1. All models use pre-lubricated sealed ball bearings for
the motor and do not require lubrication.
2. If the wheels do not rotate freely, the bearings should
be replaced by an authorised service centre.
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Cleaning
1. Keep the outside of the grinder clean by brushing grinding
dust and dirt away from all areas where the dust tends to
build up. Wear eye protection when brushing.
2. Wipe the guards and grinder with a soft damp cloth. A
mild detergent can also be used.
3. Wipe the eye shields with a soft damp cloth, making
sure not to scratch the surface. A mild detergent can also
be used.
Caution. Never use caustic agents, petrol based cleaners,
alcohol or any other cleaning agents. Do not wet down
the grinder.
General inspection
1. Regularly check that all the fixing screws are tight. They
may vibrate loose over time.
Repairs
1. If the supply cord needs replacing, the task must be
carried out by the manufacturer, the manufacturer's
agent, or an authorised service centre in order to avoid
a safety hazard.
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Carefully read the entire Instruction Manual
before using this product.
Before returning this product for a
Warranty Claim or any other reason
Please Call 1300 880 001 (Australia)
or 0800 445 721 (New Zealand)
When you make your call, please have
the following information at hand:
• GMC Product Type • GMC Product Code
A GMC Service Engineer will take your call and, in
most cases, will be able to solve your problem over
the phone.
You are welcome to use this phone-in service to
make suggestions or give comments about any
GMC product.
With continuing product development changes may
have occurred which render the product received
slightly different to that shown in this instruction
manual. The manufacturer reserves the right to
change specifications without notice. Note:
Specifications may differ from country to country.
The GMC 777 Helpline operates from 7am to
7pm, 7 days a week (EST). This allows you
to contact GMC directly with any queries and
technical questions you have regarding
our products.
45–55 South Centre Road
Melbourne Airport
Victoria, Australia 3045
Tel: (03) 8346 1100 Fax: (03) 8346 1200
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