King Arthur’s Tools, 3645 Hartsfi eld Road, Tallahassee, Florida 32303 USA

Telephone:1-850-877-7650 • Fax:1-850-877-6120 • Email: [email protected]

Internet: www.katools.com • www.kingarthurstools.com • www.hooftrimmingtools.net

Protected by worldwide patents. Made in the U.S.A and Germany.

OPERATING

INSTRUCTIONS

Merlin

®

/Proxxon

®

MODEL IDENTIFICATION

King Arthur’s Tools ® includes Proxxon ® long neck angle grinders in various models for different applications. The power unit is available in both 110V/115V and 220V/240V.

The following chart easily identifi es your Proxxon ® power unit model.

SPECIFICATIONS

• Variable Speed 110-115 Volt

Merlin Model 10005 - Universal Carving Set

Merlin Model 10050 - Hoof Trimming Set

(Proxxon LW/E 38544)

Motor:

Voltage 110V-115 V- 60Hz

Power 1.0 amp/100 Watt

Unit:

Rotational Speed 6,500 up to13,000 rpm

Disc diameter

Length

Weight approx. 2”/ 50mm

11-13/32”/280mm

1.54 lb/700 grams

• Variable Speed 220-240 Volt

Merlin Model 10018 - Universal Carving Set

(Proxxon LW/E 28544)

Motor:

Voltage 220V-240V~ 50hz

Power 1.0 amp/100 Watt

Unit:

Rotational Speed 6,500 up to13,000 rpm

Disc diameter 2” / 50mm

Length

Weight

11-13/32”/280mm

1.54 lb/700grams

(Limited Stock)

All Models:

Characteristic noise emission < 78 dB (A)

Noise level may exceed 85 dB (A) during operation.

Vibration at handle < 2.5 m/s2

Class II Equipment Double Insulation

2 - MERLIN

IMPORTANT WARRANTY INSTRUCTIONS

FOR MERLIN

®

SERVICE AND REPAIR, CONTACT KING ARTHUR’S TOOLS

AT 1-800-942-1300 (USA ONLY) OR 1-850-877-7650.

DO NOT RETURN UNIT TO PROX-TECH.

LIMITED WARRANTY 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 woodcarving 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 warranty. 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.

MERLIN - 11

/PROXXON

®

10 - MERLIN

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

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

MERLIN Instructions

Congratulations and thank you for purchasing

Merlin ® , a real “Wizard Of A Tool”.

Merlin ® joins our realm of innovative tools with “The World’s Smallest Chain Saw”.

The Universal Carving Set pairs the Proxxon ® long neck angle grinder with fi ve (5) accessories. The Hoof Trimming Set pairs the grinder with three (3) accessories.

The power unit is available in a variable speed model for 110V/115V.

All models come in a molded 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.

It can be used for carving, roughening, shaping, deburring, fi ne grinding, chamfering, paint removal, rust removal, cutting small components and sharpening tools. Merlin’s accessories can be used on wood, hooves, fi berglass, foam, bone, antlers, steel, nonferrous metals, glass and ceramics.

Before putting the machine into operation, please read all the enclosed safety rules and operating instructions.

– SAFETY GUARD –

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

work. Use the correct accessories for your application. Excessive force could cause

bearing failure in the head of the grinder. The chain blades and carbide discs can be used on their face, laterally and vertically to remove, shape, shave and etch wood.

A light motion works best.

– WARNING –

OVERHEATING: Do not overwork the grinder. 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.

OVERTIGHTENING: Do not over tighten accessories or you could strip the

internal gear in the lock down switch of the aluminum gear head. Use a gentle 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!

MERLIN - 3

Variable Speed Overview

(FIG 1)

1. Locking button

2. Variable Speed control

3. ON-OFF switch

4. Unit handle

5. Connection cable with mains plug

6. Protective safety guard

7. Grinder accessories

Using The Unit

1. Switch the unit on:

Variable Speed, switch 3 - (FIG 1),

2. For Variable Speed (FIG 1) use

switch 2 to set the speed control

to a speed appropriate for the

work to be performed.

(Refer Speed Chart on Page 5)

Replacing Accessories

(FIG 3)

W A R N I N G !

Disconnect the plug from the mains before replacing any accessories. Never press the locking button if the accessory is still rotating.

1. Press the locking button 1

(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.

FIG 3

W A R N I N G !

Adjusting Protective

Safety Guard

(FIG 4)

Disconnect the plug from the mains before the following.

1. Release fastening screw 1

and turn protective guard to

the correct position.

2. Retighten the fastening screw.

Ensure the accessory is

FIG 4

4 - MERLIN

Grinding Wheel Use

Good grinding performance can only be achieved using the correct and 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 bend the grinding disc into the cutting surface during cutting work.

W A R N I N G !

Do not use the cutting disc for roughening work. Risk of fracture!

Use the tungsten carbide or chain saw accessories.

Maintenance

W A R N I N G !

Disconnect the plug from the mains before performing any maintenance or cleaning work.

After Use

Clean the unit thoroughly, removing all wood shavings, grinding dust, hoof residue, etc with a brush or a soft cloth.

Ensure all ventilation slots are free from obstruction so....

Regularly clean the tool’s air

vents by compressed air.

Excessive accumulation of wood and hoof shavings, sawdust, powdered metal, or other foreign particles inside the motor housing may cause overheating or electrical failures.

Symbols

Important: Some of the following symbols may be used on your tool.

Please study them and learn their meaning. Proper interpretation of these symbols will allow you to operate the tool better and safer.

W

Kg min s

Ø

Symbol

V

A

Hz n

0

…/min

1, 2, 3,

…



~

Name

Volts

Amperes

Hertz

Watt

Kilograms

Minutes

Seconds

Diameter

No Load Speed

Revolutions or

Reciprocation

Per Minute

Selector

Settings

Infi nitely

Variable

Selector

Arrow

Alternating

Current

Class II

Construction

Designation/

Explanation

Voltage (potential)

Current

Frequency

(cycles per second)

Power

Weight

Time

Time

Size of drill bits, grinding wheels, etc.

Rotational speed, at no load

Revolutions, strokes, surface speed, orbits etc. per minute

Speed, torque, or position settings.

Higher number means greater speed

Speed is increasing from narrow end

Action in the direction of arrow

Type or a characteristic of current

Designates

Double Insulated

Construction tools

MERLIN - 9

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 least the speed recommended on the

tool warning label. Wheels and other accessories running over rated speed can fl y apart and cause injury.

Do not reach in the area of the

rotating wheel. The proximity of the rotating wheel to your hand may not always be obvious.

Carefully handle both the tool and individual grinding wheels to avoid chipping or cracking. Install a new grinding wheel if tool is dropped while grinding. Do not use a wheel

that may be damaged. Fragments from 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 back. Other accessories may need replacing if damaged.

We highly recommend not to hold a hoof in one hand while using the grinder with chain saw in the other hand. Use clamps to secure the hoof

whenever practical. Clamping allows you to use both hands to control the tool. If it is absolutely necessary to hold the hoof or work object, allow for suffi cient space between your hand and the spinning blades/discs.

Use clamps to support workpiece 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.

Round material such as dowel rods, pipes or tubing have a tendency to roll while being cut, and may cause the

8 - MERLIN grinder to “bite” or jump toward you.

Clamping a small workpiece allows you to use both hands to control the tool.

Inspect your hoof or workpiece before cutting. When cutting irregularly shaped objects, plan your work so it will not slip, pinch the grinder and be torn from your hand.

For example, if carving wood, make sure there are no nails or foreign objects in the workpiece. These alien materials may cause the grinder to jump.

Never start the tool when the grinder is engaged in the hoof or material.

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.

If the grinder becomes jammed or bogged down in the hoof/workpiece, 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. If the switch is left on, the grinder could restart unexpectedly causing serious injury.

Do not leave a running tool un-

attended; turn power off. Only when the accessory on the grinder comes to a complete stop is it safe to put down.

Do not grind or sand near fl ammable materials. Sparks from the wheel could ignite these materials.

W A R N I N G ! Do not use the unit on materials which contain asbestos.

Do not alter or misuse tool. Any alteration or modifi cation is a misuse and may result in serious personal injury. This product is not intended for use as a dental drill or in medical

applications. Serious personal injury may result.

Assembling and

Changing Saw Chain

Outlined below is the mounting procedure for the saw chain to be correctly fi tted to the long neck mini grinder when you want to remount it.

(Refer also to FIG 3)

1) Use the Allen key 5 to unscrew any accessories, simultaneously holding down the locking button.

2) The small fastening screw 4 with the

Allen key head fi ts through a (top) black spacer 3, which has a 10mm raised shoulder. The 10mm discs with the saw chain fi t over this shoulder.

3) Make sure the chain is secured between the discs and the chain is 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

(not over) the silver spacer (which is part of the grinder).

5) Simply tighten the screw 4 with the Allen key 5 using the lock down switch 1 to hold the chain/discs during tightening, making sure the discs are centered for proper balance. test will allow you to check this visually.

Readjust chain and discs as necessary.

It’s ready to use.

IMPORTANT

If assembled in reverse to motor direction,

MERLIN will not cut, leaving burn marks on the work piece.

ASSEMBLY OF

CHAIN AND DISCS

The two discs secure the saw chain circlet between them. For both the

8 tooth (shown) and the 4 tooth circlet.

Raker Point

Tooth

Disc

NOTE DIRECTION OF

RAKER POINT AND TOOTH

Speed Chart

Accessories Available and

Recommended Speeds

Accessory

100 Grit Flap

Disc Sander

150 Grit Flap

Disc Sander

Silicon Carbide

Grinding Disc

Aluminum Oxide

Metal Cutting Disc

Coarse Red

Carbide Abrasive Disc

Medium Yellow

Carbide Abrasive Disc

Fine Stone Garnet

Carbide Abrasive Disc

Coarse Green

“V” Edge Carbide Disc

4 Tooth Carbide

Replacement Chain

for Hooftrimming

8 Tooth Standard

Replacement Chain

4 Tooth Carbide Chain

Assembly (with discs)

8 Tooth Standard Chain

Assembly (with discs)

4 Tooth Carbide

Replacement Chain for Wood Working

4 Tooth Carbide Chain

Assembly (with discs) for Wood Working

Part #

10003

10004

10007

10008

10009

10010

10011

10012

20004

20008

21004

21008

2004MW

2104MW

Rec.

Speed

12,000 –

13,000 rpm

12,000 –

13,000 rpm

10,000 rpm

10,000 rpm

7,000 –

13,000 rpm

7,000 –

13,000 rpm

7,000 –

13,000 rpm

7,000 –

13,000 rpm

9,000 –

13,000 rpm

9,000 –

13,000 rpm

9,000 –

13,000 rpm

7,000 –

13,000 rpm

9,000 –

13,000 rpm

9,000 –

13,000 rpm

MERLIN - 5

SAVE THESE INSTRUCTIONS

GENERAL SAFETY RULES

Warning! Read and understand

all instructions. Failure to follow all instructions listed below may result in electric shock, fi re and/or serious personal injury.

Do not abuse the cord. Never use 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. Damaged cords increase the risk of electric shock.

Work Area

Keep your work area clean and well

lit. Cluttered benches and dark areas invite accidents.

Do not operate power tools in explosive atmospheres, such as in the presence of fl ammable liquids,

gases, or dust. Power tools create sparks which may ignite the dust or fumes.

Keep bystanders, children, and visitors away while operating a

power tool. Distractions can cause you to lose control.

Electrical Safety

Double Insulated tools are equipped 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, reverse the plug. If it still does not fi t, contact a qualifi ed electrician to install a polarized outlet. Do not change the plug in any way. Double Insulation 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,

ranges, and refrigerators. There is an increased risk of electric shock if your body is grounded.

Do not expose power tools to rain

or wet conditions. Water entering a power tool will increase the risk of electric shock.

6 - MERLIN

When operating a power tool outside, use an outdoor extension

cord marked “W-A” or “W”. These cords are rated for outdoor use and reduce the risk of electric shock.

Personal Safety

Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the infl uence of drugs, alcohol, or

medication. A moment of inattention while operating power tools may result in serious personal injury.

Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and

gloves away from moving parts.

Loose clothes, jewelry, or long hair can be caught in moving parts.

Avoid accidental starting. Be sure switch is off before plugging in.

Carrying tools with your fi nger on the switch or plugging in tools that have the switch on invites accidents.

Remove adjusting keys or wrenches

before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury.

Do not overreach. Keep proper footing and balance at all times.

Proper footing and balance enables better control of the tool in unexpected situations.

Use safety equipment by always wearing safety goggles or full-face

visor and dust mask. Additionally, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions. Using personal safety devices and working in safe environment reduces risk of injury. Use the tool only in ventilated area.

be suitable for one tool may become hazardous when used on another tool.

Service

Tool service must be performed only by qualifi ed repair personnel.

Service or maintenance performed by unqualifi ed personnel could result in a risk of injury and could void the warranty.

Tool Use and Care

Use clamps, vise or other practical ways to secure and support the workpiece or hoof to a stable

platform. Holding the object by hand or against your body is unstable and unsafe and may lead to loss of control.

Disconnect the plug from the power source before making any 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

persons. Tools are dangerous in the hands of untrained users.

When servicing a tool, use only identical replacement parts. Follow instructions in the Maintenance

section of this manual. Use of unauthorized parts or failure to follow

Maintenance Instructions may create a risk of electric shock or injury. Certain cleaning agents such as gasoline, carbon tetrachloride, ammonia, etc. may damage plastic parts.

SPECIFIC SAFETY RULES

Be aware of the switch location, when placing the tool down or

when picking the tool up. You may accidentally activate the switch.

Maintain tools with care. Keep cutting tools sharp and clean.

Properly maintained tools, with sharp cutting edges, are less likely to bind and are easier to control.

After changing any accessory or making any adjustments, make sure the Allen key or any screws are securely tightened but not over

Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tools operation. If damaged, have the tool serviced

before using. Many accidents are caused by poorly maintained tools.

Use only accessories that are recommended by the manufacturer

for your model. Accessories that may

Hold the grinder by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its

own cord. Contact with a “live” wire 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 is unavoidable, disconnect all fuses or circuit breakers feeding this worksite.

MERLIN - 7