# GTG22-HA G120

## Grinder

# Product Information

# General Information

WARNING

Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

- Read all Safety Information delivered together with the different parts of the system.

- Read all Product Instructions for installation, operation and maintenance of the different parts of the system.

- Read all locally legislated safety regulations regarding the system and parts thereof.

- Save all Safety Information and instructions for future reference.

In this Section

- Safety Signal Words
- Warranty
- Website
- ServAid
- Safety Data Sheets MSDS/SDS
- Product Safety Video for Grinders
- Country of Origin
- Dimensional Drawings

# Safety Signal Words

The safety signal words Danger, Warning, Caution, and Notice have the following meanings:

DANGER | DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING | WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION | CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE | NOTICE is used to address practices not related to personal injury.

# Warranty

- Product warranty will expire 12+1 months after dispatch from Atlas Copco's Distribution Center.

- Normal wear and tear on parts is not included within the warranty.

  - Normal wear and tear is that which requires a part change or other adjustment/overhaul during standard tools maintenance typical for that period (expressed in time, operation hours or otherwise).

- The product warranty relies on the correct use, maintenance, and repair of the tool and its component parts.

- Damage to parts that occurs as a result of inadequate maintenance or performed by parties other than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the warranty.

- To avoid damage or destruction of tool parts, service the tool according to the recommended maintenance schedules and follow the correct instructions.

- Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover contracts. For further information contact your local Service representative.

For electrical motors:

- Warranty will only apply when the electric motor has not been opened.

# Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on the Atlas Copco website.

Please visit: www.atlascopco.com.

# ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

- Regulatory and Safety Information

- Technical Data

- Installation, Operation and Service Instructions

- Spare Parts Lists

- Accessories

- Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

For further Technical Information, please contact your local Atlas Copco representative.

# Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

# Product Safety Video for Grinders

Learn more about safety features on Atlas Copco grinders and what measures the operator has to take for a safe operation. Click the link or scan the QR code below to view the video:

https://www.youtube.com/watch?v=XK_dHwli8-Q

# Country of Origin

For the Country of Origin, please refer to the information on the product label.

# Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

# Overview

# Main parts

Position | Part | Function
--- | --- | ---
1 | Support handle | Adjustable for a flexible working position for left or right handed operator.
2 | Autobalancer | Reduces vibrations.
3 | Wheel guard | Adjustable wheel guard allows flexible positioning. Prevents the operator to come in contact with the grinding wheel and protect the operator in the event of a bursting wheel.
4 | Spindle locking button/Wheel guard adjustment | Dual functionality. Locking spindle by pushing forward. Adjusting wheel guard by pulling backward.
5 | Data plate | Shows general information about the tool.
6 | Security mechanism | A two-step function for a safe start and stop of the tool. Press the release arm forward to release the safety lock arm.
7 | Throttle handle | Offers an ergonomic, comfortable and safe grip as well as good temperature insulation.
8 | Air adapter with strainer | Facilitates air connection handling and protects the tool from impurities.
9 | Throttle lever | Starts and stops the tool.
10 | Sign | Shows the tool's nominal speed.

# Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

# Installation

# Installation Requirements

# Air quality

Poor air quality may cause damage to the tool and reduce the performance.

- For optimum performance and maximum product life we recommend the use of compressed air with a maximum dew point of +10°C (50°F). We also recommend to install an Atlas Copco refrigeration type air dryer.

- Use a separate air filter which removes solid particles larger than 30 microns and more than 90% of liquid water. Install the filter as close as possible to the product and prior to any other air preparation units to avoid pressure drop.

- Lubrication free tools are a better choice from an environmental perspective.

- Lubrication will shorten the life time of the turbine motor and once lubricated, you will need to continue with the lubrication.

# Compressed Air Connection

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

WARNING

Compressed Air

High air pressure can cause severe damage and bodily injury.

- Do not exceed maximum air pressure.

- Make sure that there are no damaged or loose hoses or fittings.

For correct air pressure and hose size, see the Technical Product Data on - https://servaid.atlascopco.com or www.atlascopco.com.

Make sure that the hose and couplings are clean and free from dust before connecting to the tool.

# Installation Instructions

# Visual Inspection - Air Installation

Inspect the air installation visually from the supply point to the tool before use.

- Hose

- Couplings

- System pressure

- Air filter

Look for any damage that can compromise the safety of the tool.

# Visual Inspection - Tools and Accessories

Inspect the tool and its parts visually before use.
The parts in the list below may vary depending on model.

- Wheel guard or Backing pad

- Adapters, nuts or flange washers

- Support handle

- Throttle lever and security mechanism

- Autobalancer

- Spindle

Look for any damage, grease or oil leakage that can compromise the safety of the tool.

# Installation Overview

A | Recommended torque | E | Max free speed
B | Whip hose length | F | Recommended torque
C | Hose diameter |  |
D | Max working air pressure |  |

A | 10 Nm (7.4 ft-lb)
B | L = 900 mm (35") (RUBAIR16)
C | Ø16 mm (5/8")
D | 6.3 bar (-90 psig)
E | 12000 r/min (rpm)
F | 20 Nm (14.8 ft-lb)

# Operation

# Ergonomic Guidelines

Consider your workstation as you read through this list of general ergonomic guidelines to identify areas for improvement in posture, component placement, or work environment.

- Take frequent breaks and change work positions frequently.

- Adapt the workstation area to your needs and the work task.

  - Adjust for a convenient reach range by determining where parts and tools need to be located to avoid static load.

  - Use workstation equipment such as tables and chairs appropriate for the work task.

- Avoid work positions above shoulder level or with static holding during assembly operations.

  - When working above shoulder level, reduce the load on the static muscles by lowering the weight of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce the load on the static muscles by holding the tool close to the body.

  - Take frequent breaks.

  - Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.

- Adjust for a convenient field of vision that requires minimal eye and head movements.

- Use appropriate lighting for the work task.

- Select the appropriate tool for the work task.

- In noisy environments, use ear protection equipment.

- Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibration.

- Minimize exposure to reaction forces.

  - When cutting:

    A cut-off wheel can get stuck if the cut-off wheel is bent or not guided properly. Use the correct flange for the cut-off wheel and avoid bending the cut-off wheel during operation.

  - When drilling:

    The drill might stall when the drill bit breaks through. Use support handles if the stall torque is high. The safety standard ISO11148 part 3 recommends using a device to absorb a reaction torque above 10 Nm for pistol grip tools and 4 Nm for straight tools.

  - When using direct-driven screwdrivers or nutrunners:

    Reaction forces depend on the tool settings and joint characteristics. Strength and posture determine the amount of reaction force that an operator can tolerate. Adapt the torque setting to the operator's strength and posture and use a torque arm or reaction bar if the torque is too high.

- In dusty environments, use a dust extraction system or wear a mouth protection mask.

# Configuration Instructions

# Wheel configuration options

The table below shows the configuration options for different wheel types with applicable attachment parts.

For ordering number, see Spare Parts and Accessories in ServAid. For instructions on installing the wheel, see section Operating Instructions.

Pos. | Item | A. Grinding | B. Cutting-off
--- | --- | --- | ---
1 | Wheel | Type 27, Type 42 | Type 41
| Max diameter | 125 mm, 5" | 125 mm, 5"
| Thickness | 0.5–7.0 mm | 0.5–7.0 mm
| Hole diameter | 22 mm | 22 mm
| Peripherical speed | 80 m/s | 80 m/s
2 | Flange washer locking wheel | Ø 41 mm | Ø 58 mm
| Service tool | Allen key, 6 mm | Allen key, 6 mm
| Recommended torque | 20 Nm (14.8 ft-lb) | 20 Nm (14.8 ft-lb)

# Operating Instructions

# Adjusting support handle

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

Required tools:

- Allen key

Instructions

1. Loosen the support handle using an Allen key.

2. Adjust the support handle in a suitable position.

3. Tighten the support handle with the screw to 10 Nm (7.4 ft-lb).

   WARNING

   Risk of injury

   - Make sure that the wheel guard is put in a suitable position before operating the tool.

# Verifying free speed

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

WARNING

Risk of injury

- Always lock autobalancer with applicable part before starting the tool.

- Never measure free speed with a wheel attached.

- Measure the free speed daily.

Required tools:

- Allen key

- Tachometer

Instructions

1. Press the spindle lock button forward and keep it pressed while tightening the flange washer using an allen key.

2. Connect the tool to the air supply.

3. Put a tachometer in the spindle hole.

4. Start the tool and measure the speed at a pressure of 6.3 bar.

   Make sure that the throttle lever is pressed down to the bottom and measure the speed for at least 1 minute

5. Remove the tachometer.

6. Verify the free speed on the tachometer with the speed marked on the tool.

   WARNING

   Risk of injury

   - The measured speed must not exceed the stated maximum speed marked on the tool. Return the tool to an authorized service center in the event of overspeeding.

# Adjusting wheel guard

DANGER

Risk of Injury

There is a risk of injury if the tool is used without the wheel guard.

- Always use the tool with the recommended wheel guard.

- Make sure that the wheel guard is positioned correctly and not damaged.

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

Instructions

1. Pull and hold the spindle lock button.

2. Turn the wheel guard in a suitable position. Position the wheel guard between yourself and the grinding wheel.

   WARNING

   Risk of injury

   - Make sure that the wheel guard is put in a suitable position before operating the tool.

3. Release the spindle lock button. Make sure that the spindle lock pin snaps into place in one of the holes in the wheel guard.

# Installing wheel

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

Before you start the installation:

- Visually inspect that the wheel is not cracked or damaged.

- Perform a ring test of the wheel. Tap the wheel lightly with a screwdriver. Listen for a clear sound, indicating that the wheel is free from defects. Otherwise the wheel must be replaced.

- Make sure that the wheel has the appropriate hole dimensions.

- Make sure that you have the correct wheel for the application.

- Make sure that the stated maximum speed of the wheel is greater than or equal to the speed specified on the grinder.

Required tools:

- Allen key

Instructions

1. Press the spindle lock button forward and keep it pressed while turning the autobalancer into a locked position. Listen for a sound indicating correct position.

2. Press the spindle lock button and keep it pressed while removing the flange washer and the wheel, if it is installed, using the Allen key.

3. Fit the wheel on the spindle.

4. Re-attach the flange washer with the Allen key to the recommended torque.

   See section Wheel configuration options for service tools and recommended torque values.

5. Make sure that the wheel spins correctly.

DANGER

Risk of Injury

There is a risk of injury if the tool is used without the wheel guard.

- Always use the tool with the recommended wheel guard.

- Make sure that the wheel guard is positioned correctly and not damaged.

# Operating the grinder

DANGER

Risk of Injury

There is a risk of injury if the tool is used without the wheel guard.

- Always use the tool with the recommended wheel guard.

- Make sure that the wheel guard is positioned correctly and not damaged.

WARNING

Risk of injury

- Always use applicable protective equipment when working with the tool such as; eye protection, hearing protection and non skid safety shoes.

- Always wear protective gloves when replacing accessories or when making repairs.

- Make sure that the working area is kept free from other people to prevent injuries.

- Make sure that the workpiece is safely attached.

- Make sure that the air hose is not under pressure before connecting the tool to the air supply.

- Never remove or attach the throttle lever or security mechanism with tape or similar.

- Make sure that the selected combination of abrasive equipment and attachments parts correspond to national regulations.

- Make sure that the abrasive equipment is not cracked or damaged.

- Make sure that the maximum speed of the abrasive equipment is higher than or equal to the speed marked on the tool.

- Make sure that the speed of the tool is not higher than the maximum rated speed marked on the tool.

- When working with the tool, always hold the tool with two hands and in such a way that they are kept away from moving parts.

- Always operate the tool in the recommended working direction.

- Never touch any rotating parts when the tool is running or connected to the air line.

- Never use the tool above head height.

- Stop using the tool if abnormally loud noises and vibrations occur during use.

Instructions

1. Connect the tool to the air supply (if not already connected).

   Direct the air exhaust away from the operator.

2. Press the release arm forward to release the security mechanism.

   Press down the throttle lever to start the tool.

WARNING

Risk of Damage and Injury

Rotating parts may cause damage and injury

- Make sure that the tool is switched off and has stopped rotating before putting it down.

# Throttle Lever with Safety Trigger

The purpose of a throttle lever with safety trigger is to avoid unintentional start of the tool.

Flip the safety trigger to lock/unlock the safety function. Always put the throttle lever in locked position before putting away the tool.

- Make sure that the safety trigger works correctly.

- Replace the throttle lever if it does not work correctly.

- Never remove the safety trigger or lock it with tape.

# Service

# Maintenance Instructions

# Service Recommendations

Preventive maintenance is recommended at regular intervals. See the detailed information on preventive maintenance. If the product is not working properly, take it out of service and inspect it.

If no detailed information about preventive maintenance is included, follow these general guidelines:

- Clean appropriate parts accurately

- Replace any defective or worn parts

# Preventive Maintenance

# Service interval overview

The table below shows the recommended service intervals for this tool, including what parts to service after 500, 1000, and 1500 working hours, and so on.

Every 1000 hours service must only be carried out by authorized workshop or qualified service technician.

500 hours service | 1000 hours service | 1500 hours service
--- | --- | ---
Inspect tool visually | Inspect tool visually | Inspect tool visually
Change oil | Change oil | Change oil
Clean filters | Clean filters | Clean filters
| Service turbine |
| Service spindle |

## Maintenance kits

500 hours service | 1000 hours service | 1500 hours service
--- | --- | ---
Oil tube kit | Oil tube kit × 2 | Oil tube kit
Maintenance kit - 500 h | Maintenance kit - 500 h | Maintenance kit - 500 h
| Maintenance kit - 1000 h |

# Service instructions

# Changing oil

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

Required tools:

- Screwdriver TX20

- Torque wrench

Spare parts

- Service kit including oil syringe filled with Turbine Gearbox Oil 32
  (available to order from Atlas Copco).

Torque converter

- 3 Nm = 2.2 ft-lb

- 6 Nm = 4.4 ft-lb

Instructions

1. Connect the tool to the air supply (if not already connected).

   Always lock auto-balancer with applicable part before running the tool.

   Run the tool at idle speed for 60 seconds.

2. Disconnect the compressed air supply hose from the tool.

3. Remove the support handle from the tool.

4. Place the tool in a horizontal and stable position. Remove the spindle screw.

5. Remove the oil plug. Keep the tool in a horizontal position.

   Drain the oil from the tool for at least 30 seconds.

6. Fit the spindle screw in position and tighten with recommended torque.

7. Place the tool in a horizontal and stable position on the opposite side of the opening. Fill the tool with 7 ml Turbine Gearbox Oil 32 using an oil syringe (included in the service kit)

   Make sure that the tool is filled with oil within the recommended range. High oil level will cause overheating, while low oil level can cause gear damage over time.

8. Clean the magnet on the oil plug from oil and particles using a clean lint-free cloth.

   Fit the oil plug in position and tighten with recommended torque.

# Cleaning the fine air filter

Required tools:

- Vice

- Torque wrench

- Screwdriver

- Blow gun

Spare parts:

- Replace the filter at every 1000-hour service.

Instructions

1. Position the tool in a vice.

   Remove the four screws from the handle using a Torx screwdriver.

2. Remove the handle from the motor housing.

   Remove the fine air filter from the valve housing.

   Clean the fine air filter using a blow gun.

   Replace the fine air filter if any damage or malfunction is detected.

   Fit the cleaned or the new fine air filter in the valve housing.

   Proceed with caution not to release the over speed shut-off mechanism.

3. Fit the handle to the motor housing.

   Tighten the four screws in the handle to recommended torque.

# Cleaning the exhaust air filter

1. Position the tool in a vice.

   Remove the four screws from the handle using a Torx screwdriver.

2. Remove the throttle handle from the motor housing.

3. Lift under the spring plate on the valve housing using a screwdriver. Remove the motor turbine from the motor housing.

4. Remove the exhaust air filter from the motor housing.

5. Clean the exhaust air filter with a blow gun.

6. Reinsert the cleaned exhaust air filter in the motor housing.

7. Reinsert the motor in the motor housing.

8. Fit the handle to the motor housing.

9. Tighten the four screws in the handle to recommended torque.

# Cleaning the adapter with strainer

WARNING

Risk of severe injury

Air under pressure can cause injury.

- Always shut off the air supply when not in use or before any adjustments.

- Drain the hose of air pressure and disconnect the tool from air supply when not in use or before any adjustments.

- Always use the correct hose size and air pressure for the tool.

Required tools:

- Vice

- Torque wrench

- Wrench (3/8")

- Blow gun

Spare parts:

- Replace the filter at every 1000-hour service.

Instructions

1. Position the tool in a vice.

   Disconnect the air adapter from the handle using a wrench.

2. Clean the adapter strainer using a blow gun.

   Replace the adapter with strainer if any damage or malfunction is detected.

3. Assemble the cleaned or new adapter with strainer with the o-ring.

   Fit the adapter with strainer in the handle and tighten using a wrench to recommended torque.

# Lubrication Instructions

# Lubrication Guide

Use lubricants of good quality. The oils and greases listed in the lubrication table are examples of lubricants that can be recommended.

Brand | General purpose Bearings
--- | ---
BP | Energrease LS-EP2
Castrol | Spheerol EP L2
Esso | Beacon EP2
Q8 | Rembrandt EP2
Mobil | Mobilegrease XHP 222
Shell | Alvania EP2
Texaco | Multifak EP2
Molycote | BR2 Plus

# Troubleshooting

# Troubleshooting the tool

The table below shows the most common troubleshooting procedures.

The actions marked with asterisk * must only be carried out by authorized workshops or qualified service technicians.

Problem | Reason | Action
--- | --- | ---
Tool does not start | No air flow to the tool | Check air connection
| Overspeed protection device activated | *
| Motor jammed | *
Inconsistent idling speed | Unstable air pressure | Check air pressure regulator
| Worn governor | *
Low power | Low air pressure | Check air pressure
| Wrong length or dimension of supply hose | Check air connection
| Blocked filters | Clean or change the corse & fine filter
| Too humid air (high dew point) | Check the compressor
| Too much oil in gear box | Check oil level
| Worn throttle valve | *
| Worn turbine | *
| Worn governor | *
Oil in exhaust air | Lubricated air | Oil in the air is not recommended
| Leak from turbine seal | *
| Leak from O-ring on diffuser | *
| Leak from overspeed pin | *
Oil leakage at spindle | Loose screws or oil plug | Tighten screws
| Worn oil seal | *
| Damaged O-ring on plate | *
| Damaged spindle bearing | *
| Missing seal on oil plug or screws | Replace seal
Tool starts unexpectedly | Damaged throttle valve | *
| Valve pin jammed in start position | Change pin & guide
| Damaged safety lock mechanism | Change mechanism
Vibrations | Worn or damage grinding wheel | Change wheel
| Autobalancer not working properly | Change autobalancer
Too high idle speed | Governor | *
Motor housing too hot | Too much oil in gear box | Check oil level
Abnormal sound | Too little oil in gear housing | Check oil
| Damaged gear | *
| Incorrect gear play | *
| Worn motor bearings | *

# Recycling

# Environmental Regulations

When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle the components in accordance with local legislation.

Batteries shall be taken care of by your national battery recovery organization.

# Recycling information

| Part | Recycle as
--- | --- | ---
1 | Motor housing | Aluminum
2 | Motor | Aluminum
3 | Throttle handle | Aluminum
4 | Lever | Steel
5 | Screw | Steel
6 | Adapter | Steel
7 | Screw | Steel
8 | Holder | Steel
9 | Teeth washer | Steel
10 | O-ring | Rubber
11 | Support handle | Aluminum
12 | Screw | Steel
13 | Weight | Steel
14 | Spindle | Steel
15 | Screw | Steel
16 | Wheel guard | Steel
17 | O-ring | Rubber
18 | Support ring | Steel
19 | Autobalancer | Steel
20 | Flange washer | Steel