INSTRUCTION MANUAL
COPYRIGHT © 2015 ALL RIGHTS RESERVED BY KING CANADA TOOLS INC.
MODEL: 8204G
4-1/2” ANGLE GRINDER
03/2016
IMPORTANT INFORMATION
2-YEAR
LIMITED WARRANTY
FOR THIS ANGLE GRINDER
KING CANADA TOOLS
OFFERS A 2-YEAR LIMITED WARANTY
FOR NONCOMMERCIAL USE.
PROOF OF PURCHASE
Please keep your dated proof of purchase for warranty and servicing purposes.
LIMITED TOOL WARRANTY
King Canada makes every effort to ensure that this product meets high quality and
durability standards. King Canada warrants to the original retail consumer a 2-year
limited warranty as of the date the product was purchased at retail and that each
product is free from defects in materials. Warranty does not apply to defects due
directly or indirectly to misuse, abuse, normal wear and tear, negligence or
accidents, repairs done by an unauthorized service center, alterations and lack of
maintenance. King Canada shall in no event be liable for death, injuries to persons
or property or for incidental, special or consequential damages arising from the use
of our products.
To take advantage of this limited warranty, return the product at your expense
together with your dated proof of purshase to an authorized King Canada service
center. Contact your retailer or visit our web site at www.kingcanada.com for an
updated listing of our authorized service centers. In cooperation with our authorized
serviced center, King Canada will either repair or replace the product if any part or
parts covered under this warranty which examination proves to be defective in
workmanship or material during the warranty period.
NOTE TO USER
This instruction manual is meant to serve as a guide only. Specifications and
references are subject to change without prior notice.
PARTS DIAGRAM & PARTS LISTS
Refer to the Parts section of the King Canada web site for the most updated parts
diagram and parts list.
KING CANADA INC. DORVAL, QUÉBEC, CANADA H9P 2Y4
www.kingcanada.com
1. KNOW YOUR TOOL
Read and understand the owners manual and labels affixed to the tool. Learn its
application and limitations as well as its specific potential hazards.
2. DON’T USE power tools in damp or wet locations or expose them to rain. Keep work
area well lit and provide adequate surrounding work space.
3. USE RIGHT TOOL.
Don’t force the tool or the attachment to do a job for which it was not designed.
4. WEAR PROPER APPAREL.
Do not wear loose clothing, gloves, neckties or jewelry (rings, watch) because they could
get caught in moving parts. Non-slip footwear is recommended. Wear protective hair
covering to contain long hair. Roll up long sleeves above the elbows.
5. MAINTAIN TOOL WITH CARE.
Keep tool clean for best and safest performance. Follow instructions for operation and
changing accessories.
6. DISCONNECT TOOLS.
Before servicing, when changing accessories or attachments.
7. AVOID ACCIDENTAL STARTING.
Make sure the switch is in the ‘’OFF’’ position before plugging in.
8. USE RECOMMENDED ACCESSORIES.
Consult the manual for recommended accessories. Follow the instructions that
accompany the accessories. The use of improper accessories may cause hazards.
9. CHECK FOR DAMAGED PARTS.
Before further use of the tool, a guard or other parts that are damaged should be
carefully checked to ensure they will operate properly and perform their 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 parts which are damaged
should be properly repaired or replaced.
SPECIFIC RULES FOR SAFE OPERATION
1. Use specified grinding wheel: The wheel used by the grinder must be reinforced fibre
resin, with a safety linear velocity not lower than 80 meters per second. If the wheel
has been kept for more than one year, a rotational strength test should be performed
before use.
2. Pay attention to the wheel guard: This wheel guard is an important part of the tool to
ensure safety. Do not operate the tool when the wheel guard has been dismantled.
3. Places prohibiting the use of the tool: The tool must not be used in specific
environements such as environements with moisture, heat, rain or snow or in a place
with explosive gas or corrosive vapours.
4. Unplugging the tool: The tool should be unplugged after each use or before servicing
(changing parts or wheel). Do not unplug the tool by pulling on the power cord.
5. Prevent the tool from starting unexpectedly: Before putting the plug into a socket, make
sure the switch is in the OFF position. When the plug is still connected to the power
source, do not carry the tool with your finger pressing on the trigger of the switch.
GENERAL AND SPECIFIC
SAFETY INSTRUCTIONS
GETTING TO KNOW
YOUR ANGLE GRINDER
SPECIFICATIONS
Model........................................................................................................................8204G
Amperage ....................................................................................................................4.2A
Voltage........................................................................................................................120V
Cycle/Phase ................................................................................................60Hz, 1 phase
No load speed (RPM) ..............................................................................................12,000
Grinding wheel diameter............................................................................................4-1/2”
Arbor size......................................................................................................................7/8”
Weight .................................................................................................................... 4.5 lbs
1. 4-1/2” x 1/4” grinding wheel
2. Spindle lock button
3. Trigger
4. Carbon brush cap (1 of 2)
5. Dual position control handle
6. Grinding wheel guard
ELECTRICAL INFORMATION
WARNING: The warnings, cautions, and instructions discussed in this instruction manual
cannot cover all possible conditions and situations that may occur. It must be understood
by the operator that common sense and caution are factors which cannot be built into this
product, but must be supplied by the operator. Performance of this tool may vary
depending on variations in local line voltage. Extension cord usage may also affect tool
performance.
VOLTAGE WARNING
Before connecting the tool to a power source (receptacle, outlet, ect.) be sure the voltage
supplied is the same as that specified on the nameplate of the tool. If one says 120V and
the other says 115V then there will be no complications. Never try to plug a 120V tool into
a 240V outlet, or the other way around. A voltage greater than that specified on the tool
can result in SERIOUSINJURY to the user, as well as damage to the tool. If in doubt, DO
NOTPLUGINTHETOOL.
WARNING: YOUR ANGLE GRINDER MUST BE CONNECTED TO A 120V, 15-AMP,
BRANCH CIRCUIT BREAKER. FAILURE TO CONNECT IN THIS WAY CAN RESULT IN
INJURY FROM SHOCK OR FIRE.
DOUBLE INSULATION
Double insulated tools are equipped with a polarized
two-prong plug (one blade is wider than the other).
This plug will fit in a polarized outlet only one way. If
the plug does not fit fully into the outlet, reverse the
plug. If it still does not fit, contact a qualified
electrician to install a polarized outlet. Do not alter or
change the plug in any way. Double insulation
eliminates the need for three wire grounded power
supply and grounded power cords.
EXTENSION CORDS
Improper use of extension cords may cause
inefficient operation of your tool which can result
in overheating. Be sure your extension cord is
rated to allow sufficient current flow to the motor.
If you are using the tool outdoors, use an
extension cord rated for outdoor use (signified
by “WA” on the jacket).
The extension cord must have a minimum wire size depending on the amperage of the
tool and the length of the extension cord. This size is determined by its AWG (American
Wire Gauge) rating. The smaller the gauge, the greater the cable’s capacity. The amount
of cords used does not matter: Total length determines the minimum AWG rating. Every
cord must meet the AWG rating. Use the chart in Fig.2 to determine what AWG rating is
required for your situation.
Tool’s
Amperage
Rating
3-6
6-8
8-10
10-12
12-16
Cord Size in A.W.G.
Cord Length in Feet
25 50 100 150
18 16 16 14
18 16 14 12
18 16 14 12
18 16 14 12
14 12 - -
FIGURE 1
Polarized plug
Polarized outlet
FIGURE 2
INSTALLING HANDLE & GRINDING WHEEL
1) Install the handle (A) Fig.3 on either side of the
motor housing, based on the application or if you
are right or left handed.
2) Press and hold down the spindle lock button (B)
Fig.3.
3) Remove the outer flange (A) Fig.4 with the
included spanner wrench (A) Fig.5 by turning
counterclockwise.
4) Install grinding wheel (B) Fig.4 against the inner
flange (C).
5) Secure new grinding wheel with outer flange (A) by
pressing and holding spindle lock button and using
spanner key (A) Fig.5 to fix into place (clockwise).
6) If the safety guard (A) Fig.6 is not in the most
suitable position for the operation, it is
recommended to shift the position of the safety
guard by loosening the fixing screw (B), shift safety
guard position and secure the fixing screw.
Warning! If you wish to install a wire brush, the safety
guard must be removed. Reinstall safety guard once
the wire brush operation is finished.
OPERATION
1) To turn the power on, firmly hold the angle grinder
with one hand. Use the other hand to hold the side
handle. Push the on/off trigger (C) Fig.3 forward to
start the angle grinder.
2) Use the side handle to help steady the tool and
assist movement.
3) Different grinding angles produce different
finishes. For rough stock, grind at a 30º angle. For
finishing operations, grind at a 15º angle.
4) Do not use excessive force, let the grinding wheel
do most of the work.
5) Once the grinding operation is finished, push the
trigger backward to stop the grinder, wait until the
grinding wheel has come to a complete stop before
you put the tool down.
Figure 4
Figure 3
ASSEMBLY & OPERATION
Figure 5
Figure 6
MAINTENANCE
INSPECTING/REPLACING CARBON BRUSHES
Remove and check the carbon brushes regularly
(normally after 50 hours of use). The carbon brushes
are installed inside the motor housing. Using a
screwdriver, remove the carbon brush caps (A) Fig.7
on both sides of the motor housing.
Remove the carbon brush (A) Fig.8 from the motor
housing and inspect it. Repeat this step for the
second carbon brush. Carbon brushes need to be
replaced once they wear down to the small limit mark
as shown in Fig.8. Keep the carbon brushes clean
and free to slip in the holders.
If they have worn down to the limit mark, purchase a
set of identical replacement carbon brushes (both
carbon brushes should be replaced at the same
time). Install new carbon brushes and reinstall the
carbon brush caps.
If you are unsure about these instructions, we
recommend that you get a qualified service technician to replace the carbon brushes.
Contact a King Canada service centre.
FREQUENT INSPECTION AND MAINTENANCE
The tool should be inspected and maintained frequently. Check and make sure the power
cord, internal wires, plug and switch are in good condition. Make sure the insulation
resistance is within normal limits, contact between the brushes and the commutator are
good, and that there is no short-circuit or breakage of the armature and stator windings.
Check the grinding wheel, bearings and driving parts also.
Grease the tool frequently. Grease can be volatilized and therefore the grease in the gear-
box should be kept clean, replenish or renew as needed.
Do not allow brake fluid, gasoline, petroleum-based products such as penetrating oils to
come in contact with plastic parts. They contain chemicals which can damage, weaken or
destroy the motor housing, thus compromising the intergrity of the double insulation.
Inspect mounting screws regularly, making sure they are properly tightened. Tighten all
loose screws before operating.
Service should be done by a qualified service technician using identical replacement parts.
Figure 8
Figure 7
Limit mark
TROUBLESHOOTING
Faults Causes Solution
1. Motor fails to
run.
2. Motor gives
out an abnormal
sound, will not
start or runs
slowly.
3. Head
enclosure gets
too hot.
1. Power supply broke off or
connections loosened.
2. Switch contact is not good.
3. Windings of armature or
stator burnt out.
4. Stator short-circuited.
1. Switch contactors burnt out.
2. Mechanical obstruction.
3. Too much pressure on tool,
motor is overloading.
4. Armature slightly short-
circuited or opencircuited.
1. Lack of grease in head
enclosure or the grease is
contaminated by dirt.
2. Mashing of the gears too
tight or entrance of foreign
matters.
1. Reconnect or change
connections.
2. Repair or replace switch.
3. Replace the windings.
4. Weld broken leadout or
rewind the winding.
1. Repair or replace the switch.
2. Inspect the mechanical parts.
3. Reduce pressure on tool.
4. Replace or repair the
armature.
1. Add or change grease.
2. Inspect gears or clean off
foreign matters.
Faults Causes Solution
4. Motor runs,
but is not turning.
5. Casing gets
too hot.
6. Heavy spark-
ing occurs on the
commutator.
1. Gear shaft or woodruff key
is broken.
2. Nut at small bevel gear is
not tightened.
1. Working load is too heavy.
2. Winding got wet.
3. Not properly assembled.
4. Regulated voltage drop.
1. Armature short-circuited or
opencircuited.
2. Surface of commutator is
not clean.
1. Inspect if the gear shaft or
the woodruff key is broken.
2.Tighten the nut.
1. Reduce pressure on the tool.
2. Dry the motor.
3. Inspect if the armature is
blocked or touches the stator
core.
4. Regulate supply voltage.
1. Repair the armature.
2. Clean off foreign matters
and make the surface of the
commutator is clean and
smooth.
/
