Page 1
IMPORTANT WARRANTY INSTRUCTIONS
FOR MERLIN
®
SERVICE AND REPAIR, CONTACT KING ARTHUR’S TOOLS
1-800-942-1300
(USA ONLY) OR
1-850-877-7650
DO NOT RETURN UNIT TO PROX-TECH.
of Merlin
®
/Proxxon
®
Long Neck Angle Grinder for Home Use
King Arthur’s Tools
®
(“Seller”) warrants to the original purchaser only, that the Proxxon
®
long neck mini angle grinder, which is the power unit for the Merlin
®
miniature woodcarv-
ing set, will be free from defects in material or workmanship for a period of one year from
the date of purchase. Seller’s sole obligation and your exclusive remedy under this limited
warranty and, to the extent permitted by law, any warranty or condition implied by law,
shall be the repair or replacement of parts, without charge, which are defective in material
or workmanship and which have not been misused, carelessly handled, or misrepaired by
persons other than Seller and Authorized Service Station.
In the unlikely event of a failure of a product to conform to this written warranty, please
take the following action:
1. DO NOT return your product to the place of purchase.
2. Securely package the product by itself and return the product only,
freight prepaid, along with:
3. A copy of your dated proof of purchase (please keep a copy for yourself).
4. A written statement about the nature of the problem.
5 Your name, address and phone number to:
King Arthur’s Tools, 3645 Hartsfi eld Road, Tallahassee, FL 32303
We recommend that the package be insured against loss or in transit damage for which
we cannot be responsible. Damage to the product resulting from tampering, accident,
abuse, negligence, unauthorized repairs or alterations, unapproved attachments or other
causes unrelated to problems with material or workmanship are not covered by this war-
ranty. Any implied warranties shall be limited in duration to one year from date of purchase.
No employee, agent, dealer or other person is authorized to give any warranties on behalf
of Merlin
products from King Arthur’s Tools. King Arthur’s Tools makes no other warranty
of any kind whatever, express or implied, and all implied warranties of merchantability and
fi tness for a particular purpose which exceed the above mentioned obligation are hereby
disclaimed by King Arthur’s Tools and excluded from this limited warranty. Some states
in the U.S. and some Canadian provinces do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to you. In no event shall Seller be
liable for any incidental or consequential damages (including but not limited to liability for
loss of profi ts) arising from the incidental or consequential damages. This limited warranty
applies only to the Proxxon long neck angle grinder and the accessories included in the
Merlin Universal Carving Set or the Merlin Hoof Trimming Set sold within the United States
of America, Canada and the commonwealth of Puerto Rico. For warranty coverage within
other countries contact your local Merlin distributor. Repairs made necessary by normal
wear or abuse, or repair for product outside the warranty period, if they can be made, will
be charged at regular service prices.
OPERATING
®
/Proxxon
®
Variable Speed
Telephone:1-850-877-7650 • Fax:1-850-877-6120 • Email: katools@aol.com
Protected by worldwide patents. Made in the U.S.A and Germany.
Page 2
Part # Designation
28547 – 1 Screw
28547 – 2 Washer
28547 – 3 Grinding wheel
(accessories)
28547 – 4 Screw
28547 – 5 Guard plate
28547 – 6 Fitting piece
28547 – 7 Flange
28547 – 8 Screw
28547 – 9 Hexagon nut
28547 – 10 Circlips
28547 – 11 Spring washer
28547 – 12 Ball bearing
28547 – 13 Shaft (short)
28547 – 14 Gear pair
28547 – 15 Ball bearing
28547 – 16 Ball bearing
28547 – 17 Nut
28547 – 18 Locking button
SPECIFICATIONS
• Variable Speed 110-115 Volt
Voltage 110V-115 V- 60Hz
Weight 1.54 lb/700 grams
• Fixed Speed 110-115 Volt
Voltage 110V-115 V~ 60Hz
Weight 1.21 lb (550 grams)
• Variable Speed 220-240 Volt
Voltage 220V-240V~ 50hz
Weight 1.54 lb/700grams
• Fixed Speed 220-240 Volt
Voltage 220V-240V~ 50hz
Weight 1.21 lb (550 grams)
All Models:
Noise level may exceed 85 dB (A) during operation.
Vibration at handle < 2.5 m/s2
Class II Equipment Double Insulation
®
includes Proxxon
®
long neck angle grinders in various models for
different applications. The power unit is available in both a fi xed speed model and a
variable speed model for 110V/115V and a fi xed speed model only for 220V/240V.
The following chart easily identifi es your Proxxon
®
®
/PROXXON
®
Model # 10030
Model # 10040
Model # 10060
Model # 10070
Part # Designation
28547 – 19 Shaft (long)
28547 – 20 Gear head with
locking button
38547 – 21 Motor fastening
scews
28547 – 22 Protective strip
38547 – 23 Motor housing incl.
protective strip
28547 – 24 Fan
28547 – 25 Centering ring
38547 – 26 Motor incl.Pinion gear
28547 – 27 Support ring
28547 – 28 Board
28547 – 29 Rear housing cover
28547 – 30 Power cord incl.
plug and grommet
28547 – 31 Switch
28547 – 32 Housing screw
28547 – 33 Bow
Page 3
®
®
Instructions
Merlin
®
, a real “Wizard Of A Tool”.
®
joins our realm of innovative tools with “The World’s Smallest Chain Saw”.
The Universal Carving Set pairs the Proxxon
®
accessories. The Hoof Trimming Set pairs the grinder with three (3) accessories. The
case with specifi c model accessories and an Allen key for mounting and disassembly.
Additional accessories available from King Arthur’s Tools fi t all models and allow Merlin
®
to be used for a wide variety of applications by simply changing the accessories.
The Merlin/Proxxon
®
long neck angle grinder is ideal for miniature woodcarving, hoof
trimming, taxidermy, model making, tool making, mold making and minor vehicle repairs.
accessories can be used on wood, hooves, fi berglass, foam, bone, antlers, steel, non-
ferrous metals, glass and ceramics.
operating instructions.
– SAFETY G U A R D –
The angle grinder comes fi tted with a miniature chainsaw blade and is ready for use.
The position of the safety guard has been rotated to the correct position.
DO NOT
REMOVE THE SAFETY GUARD WHEN USING THE CHAINSAW BLADE OR ANY
ACCESSORY AND ALWAYS OPERATE THEM WITH THE GUARD IN THE 23
o
TO 45
o
POSITION.
The risk of kickback or binding, however small, is greatly increased with no
safety guard. The guard also protects operator from broken grinding wheel fragments.
IF YOU REMOVE THE SAFETY GUARD, DON’T USE THESE ACCESSORIES.
We caution you not to force the accessories into the work piece.
Let the tool do the
Excessive force could cause
bearing failure in the head of the grinder.
The chain blades and carbide discs can be
A light motion works best.
– WA R N I N G –
If the unit overheats, switch it off and
allow it to cool. Failure to do so could burn out the motor. Also on a regular basis,
blow out the motor to prevent clogging which could contribute to overheating.
Do not over tighten accessories or you could strip the
internal gear in the lock down switch of the aluminum gear head.
touch to secure the accessory – not brute force! In the event of failure, contact King
Arthur’s Tools. Look after your tool and your tool will look after you!
®
/PROXXON
®
Variable Speed
Model # 10005
Model # 10018
Model # 10050
Part # Designation
28544 – 1 Screw
28544 – 2 Washer
28544 – 3 Grinding wheel
(accessories)
28544 – 4 Screw
28544 – 5 Guard plate
28544 – 6 Fitting piece
28544 – 7 Flange
28544 – 8 Screw
28544 – 9 Circlip
28544 – 10 Spring washer
28544 – 11 Ball bearing
28544 – 14 Ball bearing
28544 – 15 Nut
28544 – 18 Motor fastening
screws
28544 – 19 Protective Strip
28544 – 20 Locking button
28544 – 21 Fan
28544 – 24 Control knob
Part # Designation
28544 – 25 Switch
28544 – 26 Centering ring
38544 – 27 Motor incl.Pinion gear
28544 – 28 Support ring
38544 – 29 Control unit
28544 – 30 Rear housing cover
28544 – 31 Bow
38544 – 32 Power cord incl.
plug and grommet
28544 – 33 Ball bearing
28544 – 34 Gear pair
28544 – 35 Shaft (short)
28544 – 36 Shaft (long)
28544 – 37 Gear head with
locking button
28544 – 38 Motor housing incl.
protective strip
28544 – 39 Hexagon nut
28544 – 40 Housing screw
38544 – 41 Label
Page 4
Variable Speed Overview
2. Variable Speed control
3. ON-OFF switch
4. Unit handle
5. Connection cable with mains plug
6. Protective safety guard
2. ON-OFF switch
3. Unit handle
4. Connection cable with mains plug
5. Protective safety guard
6. Grinder accessories
Variable Speed, switch
3 - (
2 - (
).
2. For Variable Speed (FIG 1) use
switch
to set the speed control
to a speed appropriate for the
work to be performed.
(Refer Speed Chart on Page 5)
accessories. Never press the
(FIG 3)
2. Turn the fastening screw 4
using an Allen key 5 until the
locking button engages.
3. Undo the fastening screw 4,
remove the centering disc 3
and the accessory 2 (e.g.
grinding disc).
4. Fit the new
accessory
and ensure it
is properly
seated in the
centering disc
shoulder 3.
5. Press locking
button 1 and
secure, but
do not over-
tighten the
fastening screw 4.
Adjusting Protective
Safety Guard
and turn protective guard to
the correct position.
2. Retighten the fastening screw.
Ensure the accessory is
properly
seated in
the cen-
tering disc
shoulder 3
(FIG 3).
constant rotational speed. To achieve
the best results when roughening,
apply the grinding disc to the grinding
surface at an angle of between 30°
and 40° and move evenly back and
forth over the workpiece. Do not
cutting surface during cutting work.
saw accessories.
cleaning work.
After Use
all wood shavings, grinding dust, hoof
from obstruction so....
Regularly clean the tool’s air
overheating or electrical failures.
Symbols
Some of the following
symbols may be used on your tool.
these symbols will allow you to
operate the tool better and safer.
Symbol
V
Volts
Voltage (potential)
A
Amperes
Current
(cycles per second)
W
Watt
Weight
min
Time
s
Seconds
Time
Ø
Size of drill bits,
grinding wheels, etc.
n
0
at no load
surface speed, orbits
etc. per minute
Selector
Settings
Speed, torque, or
position settings.
means greater speed
Variable
Selector
Speed is increasing
from narrow end
Arrow
Action in the
direction of arrow
Alternating
Current
Type or a
characteristic
of current
Class II
Construction
Construction tools
Page 5
8 - MERLIN
Assembling and
correctly fi tted to the long neck mini
grinder when you want to remount it.
5
to unscrew any
accessories, simultaneously holding
down the locking button.
2) The small fastening screw
with the
Allen key head fi ts through a (top) black
spacer
3
shoulder. The 10mm discs with the saw
chain fi t over this shoulder.
3) Make sure the chain is secured
facing the right direction with the raker
on the left. Another check is to make
sure that the number 25 stamped on
tang of the chain is face down.
4) The bottom saw chain disc
sits on
5) Simply tighten the screw
with
the Allen key
5
using the lock down
switch
to hold the chain/discs during
tightening, making sure the discs are
centered for proper balance.
A quick on/off
test will allow you to check this visually.
to motor direction,
ASSEMBLY OF
The two discs secure the saw chain
circlet between them.
For both the
NOTE DIRECTION OF
RAKER POINT AND TOOTH
Speed Chart
Accessories Available and
Recommended Speeds
Accessory
Speed
Silicon Carbide
Grinding Disc
Aluminum Oxide
Coarse Red
Carbide Abrasive Disc
7,000 –
Carbide Abrasive Disc
7,000 –
Carbide Abrasive Disc
7,000 –
Coarse Green
“V” Edge Carbide Disc
7,000 –
4 Tooth Carbide
for Hooftrimming
20004
9,000 –
8 Tooth Standard
20008
9,000 –
4 Tooth Carbide Chain
Assembly (with discs)
21004
9,000 –
8 Tooth Standard Chain
Assembly (with discs)
21008
7,000 –
4 Tooth Carbide
for Wood Working
2004MW
9,000 –
4 Tooth Carbide Chain
Assembly (with discs)
for Wood Working
2104MW
9,000 –
Always disconnect the power cord
from the power source before making
any adjustments or attaching any
accessories.
You may unexpectedly
cause the grinder to start, leading to
serious personal injury.
Accessories must be rated for at
tool warning label.
Wheels and other
accessories running over rated speed
can fl y apart and cause injury.
The proximity of the
always be obvious.
chipping or cracking. Install a new
grinding wheel if tool is dropped
while grinding. Do not use a wheel
that may be damaged.
a wheel that bursts during operation
will fl y away at great velocity possibly
striking you or bystanders.
If a chain
tooth becomes jagged, simply
sharpen it with a few strokes of
the diamond fi le to bring the edge
We highly recommend not to hold
a hoof in one hand while using the
grinder with chain saw in the other
whenever practical.
you to use both hands to control the
tool.
for suffi cient space between your
whenever practical. Never hold a
small workpiece in one hand and the
tool in the other hand while in use.
Allow for suffi cient space between
your hand and the spinning grinder.
while being cut, and may cause the
grinder to “bite” or jump toward you.
to use both hands to control the tool.
work so it will not slip, pinch the
grinder and be torn from your hand.
there are no nails or foreign objects in
the workpiece. These alien materials
The accessory’s cutting edge may grab
the cutting object causing loss of control
of the cutter and possible injury to the
animal.
Avoid bouncing and snagging the
accessories, especially when working
corners, sharp edges, etc.
This can
cause loss of control and kickback.
turn the tool off by the switch. Wait
for the spinning accessory to stop
and unplug the tool, then work to
free the jammed material.
attended; turn power off.
Only when
the accessory on the grinder comes to
a complete stop is it safe to put down.
could ignite these materials.
on materials which contain asbestos.
Any
alteration or modifi cation is a misuse
and may result in serious personal
This product is not intended
for use as a dental drill or in medical
applications.
Serious personal injury
Tooth
Page 6
6 - MERLIN
Warning! Read and understand
all instructions.
Failure to follow all
Work Area
Cluttered benches and dark areas
explosive atmospheres, such as in
the presence of fl ammable liquids,
gases, or dust.
sparks which may ignite the dust
or fumes.
visitors away while operating a
Distractions can cause
you to lose control.
with a polarized plug (one blade is
wider than the other).
This plug will
fi t in a polarized outlet only one way. If
the plug does not fi t fully in the outlet,
contact a qualifi ed electrician to install
a polarized outlet. Do not change the
eliminates the need for the three
wire grounded power cord and
grounded power supply system.
Avoid body contact with grounded
surfaces such as pipes, radiators,
There is
an increased risk of electric shock if
your body is grounded.
or wet conditions.
Water entering
a power tool will increase the risk of
electric shock.
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.
When operating a power tool
outside, use an outdoor extension
cord marked “W-A” or “W”.
These
cords are rated for outdoor use and
Stay alert, watch what you are
doing and use common sense
when operating a power tool. Do
the infl uence of drugs, alcohol, or
A moment of inattention
while operating power tools may result
clothing or jewelry. Contain long
gloves away from moving parts.
can be caught in moving parts.
Avoid accidental starting. Be sure
switch is off before plugging in.
switch or plugging in tools that have
the switch on invites accidents.
A wrench
or a key that is left attached to a
footing and balance at all times.
situations.
wearing safety goggles or full-face
visor and dust mask.
Additionally,
appropriate conditions. Using personal
safety devices and working in safe
environment reduces risk of injury. Use
the tool only in ventilated area.
Tool Use and Care
ways to secure and support the
workpiece or hoof to a stable
or against your body is unstable and
adjustments, changing accessories,
or storing the tool.
Such preventive
safety measures reduce the risk of
starting the tool accidentally.
Store idle tools out of reach of
children and other untrained
Tools are dangerous in
the hands of untrained users.
cutting tools sharp and clean.
cutting edges, are less likely to bind
and are easier to control.
of moving parts, breakage of
damaged, have the tool serviced
caused by poorly maintained tools.
for your model.
Accessories that may
Service
Tool service must be performed
only by qualifi ed repair personnel.
Service or maintenance performed
warranty.
When servicing a tool, use only
section of this manual.
cleaning agents such as gasoline,
carbon tetrachloride, ammonia, etc.
SPECIFIC SAFETY RULES
when placing the tool down or
when picking the tool up.
You may
accidentally activate the switch.
After changing any accessory or
sure the Allen key or any screws
are securely tightened
tightened.
tightened.
gripping surfaces when performing
an operation where the cutting tool
own cord.
will make exposed metal parts of the
tool “live” and shock the operator. If
cutting into existing walls or other blind
areas where electrical wiring may exist
circuit breakers feeding this worksite.
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