Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these
instructions, and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE
THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR
PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
1. SAFETY
1.1. ELECTRICAL SAFETY.
WARNING! It is the user’s responsibility to check the following:
9 Check all electrical equipment and appliances to ensure that they are safe before using. Inspect power supply leads, plugs and
all electrical connections for wear and damage. Sealey recommend that an RCD (Residual Current Device) is used with all electrical
products.
Electrical safety information. It is important that the following information is read and understood:
9 Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply.
9 Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure that they are secure.
Important: Ensure that the voltage rating on the appliance suits the power supply to be used and that the plug is tted with the
correct fuse.
8 DO NOT pull or carry the appliance by the power cable.
8 DO NOT pull the plug from the socket by the cable.
8 DO NOT use worn or damaged cables, plugs or connectors. Ensure that any faulty item is repaired or is replaced immediately by a
qualied electrician.
If the cable or plug is damaged during use, switch off the electricity supply and remove from use.
Ensure that repairs are carried out by a qualied electrician.
1.2. GENERAL SAFETY
WARNING! Disconnect the grinder from the mains power, and ensure the grinding wheels are at a standstill before attempting to
change accessories, service or perform any maintenance.
8 DO NOT use a damaged accessory. Before each use, inspect the accessory such as abrasive wheels for chips and cracks.
8 DO NOT operate the grinder if any parts are damaged or missing as this may cause failure and/or personal injury.
▲ DANGER! DO NOT use a damaged wheel as it is dangerous and may cause damage and/or serious personal injury.
WARNING! Only persons qualified under the “Abrasive Wheels Regulations” and holding a current grinding wheel certificate are to
change or dress grinding wheels. Unplug grinder from mains power and refer to Section “Grinding Wheels” below for details.
9 After inspecting and installing an accessory, position yourself and bystanders away from the plane of the rotating accessory and run
the power tool at maximum no-load speed for one minute. Damaged accessories will normally break apart during this test time.
9 The rated speed of the accessory must be at least equal to the maximum speed marked on the grinder. Accessories running faster
than their rated speed can break and y apart.
9 Never grind on the sides of a grinding wheel. Grinding on the side can cause the wheel to break and y apart.
9 Only use accessories with a diameter and maximum thickness specied in the Specication section of this manual.
9 Bench grinders must always be stable and secure e.g. xed to a bench or the like.
9 Grinding wheels must be correctly mounted and free of defects before use (ring tested).
9 Spark arrestors and work rests must be adjusted frequently so as to compensate for the wear of the wheel.
WARNING! Keep all guards and holding screws in place, tight and in good working order. Check regularly for damaged parts.
A guard or any other part that is damaged should be repaired or replaced before tool is next used. The eye shields are a mandatory
fitting when grinder is used in premises covered by the Health & Safety at Work Act.
9 Distance between the spark arrestor/work rest and the wheel must be kept as small as possible and in any case no greater than
2mm.
9 Worn wheels must be replaced when the 2mm gap above can no longer able to be maintained.
9 For tools with two spindles: always use the tool with accessories on both spindles in order to limit the risk of contact with the rotating
spindle.
9 Always use the guard, work rest, transparent screen and spark arrestor as required for the accessory(ies).
9 Damaged or deeply grooved wheels must be replaced.
9 Always adjust the work rest so that the angle between the work rest and the tangent of the accessory is always greater than 85°.
9 Grinding wheels must always be handled and stored in the correct manner.
9 Maintain the grinder in good condition and check moving parts alignment regularly.
9 Replace or repair damaged parts. Use recommended parts only. Non-authorised parts may be dangerous and will invalidate the warranty.
9 Locate grinder in a suitable working area, keep area clean, tidy and free from unrelated materials. Ensure adequate lighting.
9 Before each use check grinding wheels for condition. If worn or damaged replace immediately.
BG200XL.V2 Issue 2 13/11/23
Original Language Version
© Jack Sealey Limited
Refer to
instructions
Wear eye
protection
Wear a
mask
Ø200MM WORKSHOP BENCH GRINDER 600W
MODEL NO: BG200XL.V2
Wear ear
protection
WARNING! Always wear approved eye or face protection when operating the grinder.
9 Use breathing protection in accordance with COSHH regulations if fumes or dust pose a hazard. Wear ear defenders if necessary.
9 Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
9 Remove ill fitting clothing. Remove ties, watches, rings and other loose jewellery and contain and/or tie back long hair.
9 Keep children and unauthorised persons away from the working area.
8 DO NOT use the grinder for a task it is not designed to perform.
WARNING! DO NOT grind any materials containing asbestos.
8 DO NOT switch on the grinder whilst the wheel is in contact with the workpiece.
8 DO NOT get the grinder wet or use in damp or wet locations or areas where there is condensation.
8 DO NOT use grinder where there are flammable liquids, solids or gases, e.g. paint solvents and including waste wiping or cleaning rags etc.
8 DO NOT touch the workpiece close to the ground surface as it will be very hot. Allow to cool. The workpiece may also be very sharp.
8 DO NOT operate the grinder when you are tired, under the influence of alcohol, drugs or intoxicating medication.
8 DO NOT leave the grinder operating unattended.
9 When not in use switch off the grinder, disconnect from the mains power supply and clean the machine and working area.
2. INTRODUCTION
Fitted with copper wound induction motor. Suitable for general workshop grinding and sharpening use. Two aluminous oxide
grinding stones, coarse and ne. Fitted with stone guards and spark arrestors. Eye shields included. Supplied with 3-pin plug..
3. SPECIFICATION
Model No ...................................................BG200XL.V2
Axle Diameter .......................................................16mm
Fuse Rating: ..............................................................5A
Motor power: .........................................................600W
Grinder wheel ......................................200mm Diameter
...................................................................25mm Width
.....................................................................25mm Bore
No Load Speed ................................................2850rpm
Plug Type: ..............................................................3-Pin
Power Supply Cable Length: ..................................1.6m
Supplied with: ................................................ x2 Wheels
Supply: ...................................................................230V
4. ASSEMBLY
Unpack the product and check contents Should there be any damaged or missing parts
contact your supplier immediately.
WARNING! Before assembly check to ensure grinder is unplugged from mains.
4.1. EYESHIELD
4.1.1. Remove retaining screws (fig 1. A) from the eyeshield bracket.
4.1.2. Position the eyeshield bracket on the underside of the wheel cover and align holes (fig 2)
4.1.3. Fix eyeshield to cover with screws (fig 2.1). If the shield is loose and drops down, tighten
shield screws (fig 3.2)
4.1.4. Loosen screw (fig 3.1.) and adjust the arrestor so it is 2mm from the wheel face (fig 4).
4.1.5. Securely tighten arrestor screw (fig 3.1).
4.2. TOOL REST.
Note: Some models may already have the tool rest assembled, but wheel clearance must still
be checked.
4.2.1. Take tool rest (fig 5) and align it with bolt slot on the inside of the grinding wheel cover (X).
4.2.2. Pass bolt (A) through both slots and place washers (B) onto bolt.
4.2.3. Position the rest at a maximum of 2mm from the wheel surface and secure the assembly by
tightening knob (C).
4.2.4. Turn the grinding wheels by hand to ensure clearance of above items.
4.3. Installation.
4.3.1. Securely bolt the grinder to a fireproof workbench using the base holes as a template. Check that
all assembly nuts and bolts are secure then read section 5 (grinding wheels) before use.
5. GRINDING WHEELS
5.1. MANDATORY SAFETY INSTRUCTIONS. (The following instructions must be observed together
with chapter 1 safety).
▲ DANGER! use of a damaged wheel is dangerous and may cause damage or personal injury.
WARNING! Ensure grinder is unplugged from the mains power supply before attempting to
change grinding wheels (or wheel).
5.1.1. Only persons qualified under the “Abrasive Wheels Regulations” and holding a current grinding wheel
certificate are authorised to change and dress grinding wheels.
5.1.2. Grinding wheels used with machine must be of an adequate speed rating and suitable for the
material to be ground.
5.1.3. Ensure the cutting wheel’s maximum speed specification is higher than that indicated on the machine
data plate.
5.1.4. Check grinding wheels are secure, and the wheel is not worn or damaged, that there are no fissures or
cracks. If damaged replace immediately.
5.1.5. Ensure replacement wheel is not damaged in any way such as cracks, deformations or splinters etc.
5.1.6. Also check the mounting flanges to ensure they are not deformed, burred or chipped. Damaged items
must NOT be used as they may cause irregular pressure on the wheel which may cause wheel to break.
BG200XL.V2 Issue 2 13/11/23
Original Language Version
© Jack Sealey Limited
g.1
g.2
g.3
g.4
g.5
8 DO NOT over tighten a wheel. Never tamper with a wheel in order to adapt it to a different size holder.
5.1.7. Install a new wheel as in 5.2. Once mounted on the grinder test the wheel before use by facing the
grinder in a safe direction (point away from yourself, others and vulnerable items) and run for a short
time. Dress the wheel if necessary.
5.2. Wheel Changing Procedure.
WARNING! unplug grinder from the mains power supply before changing wheel.
5.2.1. Raise the eye shield up, and away from the wheel.
5.2.2. Loosen and pull the tool rest out as far as possible, but, DO NOT remove it (fig 6).
5.2.3. Remove the screws from the side of the wheel cover and remove the cover (fig 6).
5.2.4. Hold grinding wheel firmly. To protect your hands use cloth or wear gloves. Unscrew retaining nut (fig.7.1)
Note: The nut on the right side of the grinder has standard right hand thread (undo anti-clockwise).
The left side nut has a left hand thread and must be loosened by turning clockwise. It may be necessary
to strike the wrench sharply in the loosening direction with the heel of your hand to loosen the nut.
5.2.5. Remove grinding wheel washer (fig 7.2), wheel (3), washer (4) from main
spindle (5).
5.2.6. Carefully inspect the new wheel before installing to ensure there are no fissures, chips, or cracks.
WARNING! DO NOT USE A DAMAGED WHEEL.
5.2.7. Install the new wheel by reversing steps above. Ensure washers (2 & 4) are installed with the
flange on the outside.
5.2.8. Hold wheel steady and secure locking nut. DO NOT over tighten as this may crack the wheel.
5.2.9. Replace wheel cover, re-adjust tool rest to a maximum of 2mm from wheel face and tighten
securely.
Note: You do not require a certificate to change a wire wheel. Assembly is the same as with a
wheel.
6. OPERATION
6.1. PRE USE INSPECTION
Note: Use the same clearance and alignment information if your model has a wire brush.
WARNING! INSPECT THE GRINDER BEFORE OPERATING THE MACHINE. ENSURE THE GRINDER IS UNPLUGGED
FROM THE MAINS POWER BEFORE COMMENCING THE INSPECTION.
6.1.1. Check the tool rests are securely fixed and set at a maximum of 2mm from the grinding wheel.
6.1.2. Check that eye shields are in good condition, are secure and that you can see through them clearly.
6.1.3. Turn the grinding wheels by hand and check for any damage. Check they do not touch the tool rests and are correctly aligned.
If any of the above checks fail, replace, repair, or adjust as necessary before starting the grinder.
6.2. WHEEL USE
Depending on the model, grinders are supplied with one or two aluminous oxide wheels. Wheels have two grades, fine are preferred
for hard materials and a coarse wheels for soft materials.
When grinding, should surface of the wheel become “loaded” (coated with particles of the material being ground) it is probably the
wrong grade of wheel for the job.
Important reminder: Grinding wheels MUST Only be assembled by a person holding a grinding wheel certificate. Section 5.
6.3. USING THE GRINDER
WARNING! Before commencing work, ensure you have read, understood, and apply the section 1. Safety Instructions Plug grinder into
the mains power supply. Place the eyeshield in its appropriate safety location.
Switch the grinder on, and bring the workpiece slowly into contact with the spinning wheel, or wire wheel.
When you have completed your task, unplug the grinder from the mains power supply, and clean the machine ready for next use.
7. MAINTENANCE
WARNING! Ensure the grinder is unplugged from the mains power supply before performing any maintenance or service.
7.1. As the grinding wheel wears, adjust the position of the tool rests. The rest must be at a maximum of 2mm from the wheel surface.
7.2. Regularly remove the grinding wheel covers and clean out any dust and dirt.
7.3. The machine motor and bearing are sealed units and require no regular maintenance. Should you require assistance, contact your
local Sealey service agent.
7.4. For information relating to the handling and maintenance of grinding wheels refer to section 5.
g.6
g.7
BG200XL.V2 Issue 2 13/11/23
Original Language Version
© Jack Sealey Limited
BG200XL.V2 Issue 2 13/11/23
Original Language Version
© Jack Sealey Limited
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 sales@sealey.co.uk www.sealey.co.uk
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior
notice. Please note that other versions of this product are available. If you require documentation for alternative versions, please email or call
our technical team on technical@sealey.co.uk or 01284 757505.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
WEEE REGULATIONS
Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment
(WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid
waste authority for recycling information.
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted,
taken to a recycling centre and disposed of in a manner which is compatible with the environment. When the product
becomes completely unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and
dispose of the product and fluids according to local regulations.
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