Clarke CAG800B Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0616
4½” (115mm) ANGLE GRINDER
MODEL NO: CAG800B
PART NO: 6472010

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INTRODUCTION
Thank you for purchasing this CLARKE Angle Grinder.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
Your Angle Grinder has been designed to give long and trouble free service. If,
however, having followed the instructions in this booklet carefully, you
encounter problems, take the unit to your local CLARKE dealer.
CONTENTS
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
1 x Angle Grinder 1 x Pair of Disc Retaining Flanges (fitted
1 x Auxiliary Handle 115mm Grinding Disc
1 x Pin Spanner 1 x Open Grinding Disc Guard
Pair Spare Carbon Brushes 1 x Closed Cutting Disc Guard

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ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
SAFETY SYMBOLS
The following safety symbols may be found on the machine.
Wear ear protection
Wear eye protection
Not suitable for wet grinding
Read instruction manual before use
Wear hand protection

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GENERAL SAFETY RULES
WORK ENVIRONMENT
1. Keep the work area clean and well lit. Cluttered and dark areas invite
accidents.
2. Do not operate power tools in explosive atmospheres, such as in the
presence of flammable liquids, gases or dust. Power tools create sparks
which may ignite the dust or fumes.
3. Keep children and bystanders away while operating a power tool. Anyone
entering the work area must wear personal protective equipment.
Distractions can cause you to lose control and fragments of work or a
broken disc may fly away and cause injury.
4. Store power tools properly when not in use. Abrasive products should be
stored in a dry, secure place out of the reach of children
ELECTRICAL SAFETY
1. Power tool plugs must match the outlet. Never modify the plug in any way.
Do not use adapter plugs with earthed (grounded) power tools. Unmodified
plugs and matching outlets will reduce the risk of electric shock.
2. Do not expose power tools to rain or wet conditions or use discs that require
liquid lubricants. Water entering a power tool will increase the risk of
electric shock.
3. Do not abuse the power cable. Never use the cable for carrying, pulling or
unplugging the power tool. Keep the cable away from heat, oil, sharp
edges or moving parts. Damaged or entangled cables increase the risk of
electric shock.
4. When operating a power tool outdoors, use an extension cable suitable for
outdoor use. Use of a cable suitable for outdoor use reduces the risk of
electric shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when
operating a power tool. Do not use a power tool while you are tired or
under the influence of drugs, alcohol or medication. A moment of
inattention while operating power tools may result in personal injury.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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2. Use personal protective equipment. Always wear eye protection. Safety
equipment such as dust mask, non-skid safety shoes, hearing protection
and a workshop apron capable of stopping small abrasive or workpiece
fragments.
3. Avoid accidental starting. Ensure the switch is in the off position before
plugging in. Carrying power tools with your finger on the switch or plugging
in power tools that have the switch on invites accidents.
4. Remove any adjusting key or wrench before turning the power tool on. A
wrench or a key left attached to a rotating part of the power tool may
result in personal injury.
5. Do not overreach. Keep proper footing and balance at all times. This
enables better control of the power tool in unexpected situations. Dress
properly. Do not wear loose clothing or jewellery.
6. Keep your hair, clothing and gloves away from moving parts. Loose
clothes, jewellery or long hair can be caught in moving parts.Keep the
work area clean and tidy.
7. This tool vibrates with use. Vibration may be harmful to your hands or arms.
Stop using the tool if discomfort, a tingling feeling or pain occurs. Seek
medical advice before resuming use.
8. Hold the power tool by insulated gripping surfaces only, when performing
an operation where the cutting tool could contact hidden wiring or its own
cable. Contacting a live wire may make exposed parts of the power tool
live and give the operator an electric shock.
9. Never lay a power tool down until it has come to a complete standstill. The
rotating accessory may grab the surface and pull the tool out of your
control.
10. Do not run the power tool while carrying it at your side. Accidental contact
with a spinning accessory could snag on clothing and pull the tool to your
body.
11. Regularly clean the power tool’s air vents. The motor fan will draw dust
inside the housing and accumulation of material could cause electrical
hazards.
12. Avoid operator fatigue. Stop the power tool at regular intervals for a short
break to rest hands and arms.
13. Maintain your tools. Keep all handles and grips dry and clean.

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ANGLE GRINDER SAFETY INSTRUCTIONS
1. Before starting work, always consider the following: The use of hand held
angle grinders for grinding and cutting operations can present risks to the
user. Full observation of the safety instructions in this user guide is essential.
2. Before undertaking grinding or cutting operations, always consider the
following: Is the grinding/cutting work necessary? Could a different tool be
used with less risk? (e.g. a fixed controlled cutting/grinding machine). Can
the work be sensibly positioned, secured and accessed so the operator
can maintain adequate control of the tool, taking into account, for
example the possible hazards associated with potential snatch/jamming of
a cutting disc. Is the cutting task too large for a hand held tool? If in doubt,
use an alternative lower risk solution or refer to qualified trade personnel.
3. Always use the correct tool for the job. Always assess the job. You should
never force a small angle grinder to do the job of a heavy tool. Do not use
tools for purposes not intended.
4. Always position the power cable clear of the spinning disc. If you loose
control, the cable may be cut or snagged and you hand drawn onto the
spinning disc.
5. Start up speed. Always allow the angle grinder to run up to full operating
speed before applying it to the job.
6. Applying the disc to the workpiece. Never bump the angle grinder disc on
the workpiece, or let the disc hit any other objects while grinding.
7. Do not abuse the mains lead. Never carry the tool by the mains lead or pull
it to disconnect it from the mains socket. Keep the mains lead away from
heat, oil and sharp edges.
8. Secure the work. Use clamps, or vices to hold the workpiece. Failure to
secure the workpiece could result in serious injury.
9. Remove adjusting keys and wrenches. Form the habit of checking to see
that keys and adjusting wrenches are removed from the tool before
turning it on.
10. Use outdoor extension leads. When the tool is used outdoors, only use
extension leads intended for outdoor use. Always make sure that the
extension lead is correctly rated.
11. Check damaged parts. A guard or other parts that are damaged should
be properly repaired or replaced, by an authorised service centre, unless
otherwise indicated in this user guide. Have defective switches replaced
by an authorised service facility.

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12. Accessories. Only use the recommended accessories. Ensure that the
wheels and discs are fitted in accordance with the manufacturer’s
instructions.
13. Only use discs that comply with EN12413 or EN13236. Make sure that the
disc used is suitable for the no load speed of the angle grinder. See
Specifications on page 16. Check that the speed marked on the wheel
dimensions are compatible with the grinder. Check that discs are
specifically for hand held angle grinder use.
14. Sparks and particles. Ensure that sparks and particles resulting from use do
not create a hazard, Use screens where appropriate.
15. Personal protective equipment. Always use protective safety glasses and
hearing protectors. Use other protective equipment such as gloves, apron
and helmet where necessary. If working at floor level, always wear knee
pads.
16. Switching off. The disc will continue to rotate for a few seconds after the
angle grinder is switched off. Always wait until the disc has completely
stopped before putting the angle grinder down.
17. Use the disc guard. Do not use the angle grinder without the disc guard.
Make sure that the guard is securely fitted and positioned for maximum
safety before operating the angle grinder. Always use the correct guard for
cutting or grinding work as described in this manual.
18. The grinding surface of depressed centre wheels must be mounted below
the plane of the guard lip. An improperly mounted wheel that projects
above the plane of the guard lip cannot be adequately protected.
19. Holding the angle grinder. Always hold the angle grinder with both hands.
Ensure that the workpiece is kept at waist height where possible. Never use
the angle grinder between the legs whilst sitting on the floor.
20. Feed direction. For cutting, always feed the disc into the work so that an
upcutting action is achieved.
21. Spindle lock. Do not operate the spindle lock while the spindle is still
spinning.
22. Always take care to avoid kickback by maintaining a firm grip of the tool
and positioning your body and arm to resist kickback forces. Always use
the auxiliary handle for maximum control.
23. Never position your hand close to the rotating parts and take special care
when working in corners or with sharp edges, or any situation where the
disc could snag.

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DISC SAFETY INSTRUCTIONS
1. Disc speed. Check the speed of the disc before fitting to your angle
grinder. Never use a disc with a rpm speed less than the rpm speed of your
angle grinder. See specification on page 18.
2. The outside diameter and thickness of your accessories must be within the
capacity rating of the power tool. The correct size accessories can be
correctly guarded and controlled.
3. Inspect the disc before fitting. Never use a disc that is chipped, cracked or
damaged. Fragments from a broken or damaged disc can cause serious
injury. Make sure that defective discs are destroyed and not used.
4. Handling and mounting discs. Bonded abrasive products are breakable
and shall therefore be handled with utmost care. The use of damaged or
improperly mounted or used abrasive products is dangerous and can
cause serious injuries.
5. Disc usage. Always refer to the label for specified usage and observe the
safety information. Do not use for purposes other than specified. Discs for
wet cutting applications must not be used with this angle grinder.
6. Use the correct disc. Always use the correct disc for it’s intended task. Using
the incorrect disc can cause serious injury.
7. Using the disc. Allow the disc and tool to do the work. Never force the disc
onto the workpiece as this could cause kickback and/or shatter the disc
causing serious injury. Kickback can occur in the event of a disc jam.
8. Cutting discs. Do not use cutting discs for side grinding. Do not put
sideways pressure on cutting discs.
9. Do not use reducing bushes. Do not use separate reducing bushes or
adapters to adapt large hole abrasive wheels. Do not force a disc onto a
machine or alter the size of the arbor hole.
10. Never use a damaged disc. Inspect each disc before each use for chips,
cracks, excess wear. If the tool or accessory is dropped, inspect for
damage or install a new accessory. After fitting the accessory, position
yourself away from the plane of the rotating accessory and run the tool at
full speed. damages discs are likely to break apart during this test.
11. Handling and storing discs.Abrasive products shall be handled and
transported with care. Abrasive products shall be stored in such a manner
that they are not subjected to mechanical damage and harmful
environmental influences.
12. Always use undamaged mounting flanges that are of the correct size and
shape for your cutting or grinding disc. Proper flanges support the disc and
reduce the possibility of breakage.

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ELECTRICAL CONNECTIONS
Before switching the product on, make sure that the voltage of your electricity supply is
the same as that indicated on the rating plate. This product is designed to operate on
230VAC 50Hz. Connecting it to any other power source may cause damage.
This product may be fitted with a non-rewireable plug. If it is necessary to change the
fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or
damaged, the plug must not be used until a suitable replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring instructions
shown below. The old plug must be disposed of safely, as insertion into a mains socket
could cause an electrical hazard.
If the colours of the wires in the power cable of this product do not correspond with the
markings on the terminals of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal which is
marked N.
• The wire which is coloured Brown must be connected to the terminal which is
marked L.
We strongly recommend that this machine is connected to the mains supply via a
Residual Current Device (RCD)
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs yourself.
This symbol indicates that this is a Class II product, and does not
require an earth connection.
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
WARNING! The wires in the power cable of this product are
coloured in accordance with the following code:
Blue = Neutral Brown = Live
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)

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OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Spindle Lock Button 6 On/Off Trigger Switch
2 Threaded hole (for handle) 7 Auxiliary Handle
3 Rear Handle 8 Grinding Disc Guard
4 Mains Lead 9 Grinding Disc
5 Trigger Lock Button

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BEFORE USE
FITTING / ADJUSTING THE DISC GUARD
1. Slide the disc guard into place as
shown.
2. Rotate the disc guard to the
required position and secure by
tightening the screw.
3. Ensure the disc guard is securely fitted before using the grinder.
WARNING: MAKE SURE THAT THE ANGLE GRINDER IS SWITCHED OFF AND
UNPLUGGED FROM THE MAINS SUPPLY BEFORE FITTING OR REMOVING
ANY ACCESSORIES.
ENSURE THE CORRECT GUARD IS FITTED FOR EITHER A GRINDING OR A
CUTTING DISC, WHICHEVER IS BEING USED.
WARNING: THE DISC GUARD SHOULD BE FITTED SO THAT IT PROVIDES
MAXIMUM PROTECTION TO THE USER WHEN IN THE WORKING POSITION.

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FITTING AND REMOVING A DISC
1. Make sure the disc guard is fitted before you fit any cutting/grinding disc.
2. Press and hold the spindle lock as
shown on the right.
NOTE: You may need to turn the
spindle by hand to fully
engage the spindle lock.
3. Use the pin spanner supplied to
remove the outer flange.
4. Make sure that the inner flange is
fitted correctly with the raised
circular section pointing outwards
as shown and the flat section on the opposite side engages with the flat
section on the spindle.
5. Place the grinding disc over the
spindle and on top of the inner
flange.
• Place the disc onto the spindle
as shown.
• Make sure that the disc is
properly located on the inner
flange.
6. Place the outer flange over the
spindle.
• For standard concave discs make sure that the raised section of the
outer flange is pointing towards the disc.
• When using flat discs, the outer flange washer can be reversed so
that the raised section is pointing away from the disc.
7. Press and hold the spindle lock and use the pin spanner to tighten the
outer flange.
WARNING: MAKE SURE THAT THE ANGLE GRINDER IS SWITCHED OFF AND
UNPLUGGED FROM THE MAINS SUPPLY BEFORE FITTING OR REMOVING
ANY ACCESSORIES.

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FITTING THE AUXILIARY HANDLE
1. Fit the handle by screwing it into one of the 3 threaded holes on the angle
grinder.
USING YOUR ANGLE GRINDER
WARNING: FRAGMENTS FROM A BROKEN/DETACHED DISC CAN CAUSE
SERIOUS INJURY.
WARNING: DO NOT STAND DIRECTLY IN LINE WITH THE ROTATING DISC.
WARNING: DO NOT PUT SIDEWAYS PRESSURE ON CUTTING DISCS.
WARNING: ENSURE THAT THE WORKING POSITION ADOPTED DOES NOT
CAUSE OPERATOR FATIGUE WHICH MAY LEAD TO LOSS OF CONTROL OF
THE DISC AND IMPACT/SNATCH WITH SURROUNDING OBJECTS/
MATERIALS.
WARNING: WHEN CUTTING, ENSURE THE INTENDED CUTTING PATH IS
CLEAR AND WITH SUFFICIENT CLEARANCE BETWEEN SURROUNDING
OBJECTS.
WARNING: WHEN CUTTING, KEEP THE DISC STRAIGHT TO PREVENT
SNATCHING OR JAMMING.
WARNING: ALWAYS FIT THE CORRECT GUARD ACCORDING TO WHETHER
ACUTTINGORGRINDINGDISCISBEINGUSED.REFERTOPAGE14.

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THE ON/OFF SWITCH
1. To start the angle grinder, first press
and hold the safety button (1)
and then squeeze the trigger (2)
upwards.
• The disc will start instantly.
Always maintain a firm grip with
both hands.
•Youmaydamagetheangle
grinder if you do not press the
safety button first.
2. To stop the angle grinder, release the trigger.
CUTTING TIPS
• Do not force the disc through the material. Work with a feed rate
that is suited to the material being cut.
• Do not subject the cutting disc to sideways pressure.
• The direction of the cutting motion is important. Always feed the
cutting disc into the work so that it cuts in an upward direction. If you
do not do this It can result in the disc climbing out of the cut in an
uncontrolled manner and may lead to loss of control or serious injury.
GRINDING TIPS
• The key to efficient grinding is to control the pressure and surface
contact between the grinding disc and the workpiece.
• Flat surfaces are ground at an acute angle, usually 15 to 30 degrees
to the workpiece. Too great an angle causes concentration of
pressure on a small area which may gouge, or burn the workpiece.
• Allow the disc to reach full speed before grinding.
• Avoid overloading the angle grinder. If it becomes hot when being
used, allow it to run for a few minutes under no-load conditions.
WARNING: THE DISC WILL CONTINUE TO ROTATE FOR A FEW SECONDS
AFTER THE TRIGGER HAS BEEN RELEASED.
WARNING: WHEN GRINDING, ONLY USE DISCS SPECIFICALLY DESIGNED
FOR GRINDING. YOU MUST NEVER USE CUTTING DISCS TO GRIND ANY
MATERIAL.

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SELECTING THE CORRECT GUARD
An open and a closed guard is
supplied with the CAG800B.
The “open” guard is for grinding and
the “closed” one is for cutting.
The open guard should be used with
type 27, 28 and 29 discs as follows;
• Type 27 -Depressed centre
grinding wheels
• Type 28 -Depressed centre
grinding wheels cone shaped
• Type 29 -Depressed centre semi-flexible wheels
The closed guard should be used with type 1, 41 & 42 discs as follows;
• Type 1 - Straight grinding wheels
• Type 41 - Flat cutting off wheels
• Type 42 - Depressed centre cutting off wheels
SUITABLE ABRASIVE AND CUTTING DISCS
The following Clarke discs are suitable for use with the CAG800B. Always use
the correct disc type and guard for its intended task.
MAINTENANCE
CHANGING THE CARBON BRUSHES
1. The CAG800B is supplied with a replacement pair of carbon brushes for the
motor. These may be replaced after extensive use by your Clarke dealer or
a suitably qualified technician.
• Both brushes should be replaced at the same time.
Use Model No Diameter Bore Part No
Cutting & Grinding PD1 (plasma) 115mm 22mm 3052050
Metal Cutting ------------------ 115mm 22mm 6470775
Metal Grinding ------------------ 115mm 22mm 6470705
Masonry Cutting ------------------ 115mm 22mm 6470735

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CLEANING
• To maintain the best possible performance from your angle grinder,
it must be kept clean.
• To reduce fire hazard, keep the cooling vents free of debris.
• Clean the area around the spindle and mounting washer and keep
the threaded locking washer clean.
GENERAL MAINTENANCE
• Make sure that all nuts, bolts and screws are tight and secure.
• Check the secondary handle and the guard for damage.
• Always have any damaged, or worn parts repaired or replaced.
• Always have your angle grinder inspected and maintained by
qualified service personnel. Do not attempt to repair the angle
grinder unless you are qualified to do so.
SPECIFICATIONS
Model Number CAG800B
Dimensions (L x W x H) 311 x 130 x 115 mm
Weight 2.4 kg
Input Power 800 W
Disc Diameter 115 mm
Disc Bore 22 mm
Spindle Thread Size M14
No Load Speed 11000 rpm
Sound Pressure Level (LpA dB) 83.7 dB(A)
Sound Power Level (LwA dB) 94.7 dB(A)
Vibration Levels 10.2 m/s2(Main Handle) / 11.2 m/s2(Aux
handle. Uncertainty Value (K) =1.5

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PARTS LIST & DIAGRAM

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PARTS LIST & DIAGRAM
No Description No Description
1 Outer Securing Flange 26 Round Pin
2 Inner Securing Flange 27 Rotor
3 Disc Guard 28 Bearing 607
4 Square Screw 29 Bearing Leather Ring 607
5 Cross Recess Head Screw 30 Air Baffle
6Spindle 31Stator
7 Woodruff Key 3x3.7x10 32 X head ST Screw M4x 65
8 Cross Recess Head Screw M4x14 33 Housing
9 Front Cover 34 Carbon Brush
10 Bearing 6201 35 Carbon Brush Holder
11 Bearing Platen 36 X head ST Screw M3.5x5
12 Cross Recess Head Screw M4x10 37 X head ST Screw M3x10
13 Large Gear 38 Capacitor
14 Circlip 10 dia 39 Switch
15 Slippery bearing 40 Strain Gland
16 Gearbox 41 Cable Sleeve
17 Split Washer 15 dia 42 Cable
18 Spring for Spindle Lock 43 X head ST Screw 4x12
19 Spring Lock 44 Left Handle
20 Cross Head s/t screw 45 Right Handle
21 Bearing 608 46 X head ST Screw 4x16
22 Bearing Platen 47 Auxiliary Handle
23 M8 Nut 48 Spanner
24 Spring Washer 8mm 49 Disc
25 Small Gear

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DECLARATION OF CONFORMITY