Clarke CAG900 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
Model No. CAG900
PART NO: 6470144
GC0614
ANGLE GRINDER

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
INTRODUCTION
Thank you for purchasing this CLARKE Angle Grinder.
Before attempting to use the machine, 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.
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.
ENVIRONMENTAL PROTECTION
Do not dispose of this product with general household waste.
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.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
TABLE OF CONTENTS
INTRODUCTION ..................................................................................2
GUARANTEE ........................................................................................2
ENVIRONMENTAL PROTECTION .........................................................2
TABLE OF CONTENTS ..........................................................................3
GENERAL SAFETY RULES ..................................................................... 4
ANGLE GRINDER SAFETY INSTRUCTIONS ...........................................6
DISC SAFETY INSTRUCTIONS ..............................................................7
ELECTRICAL CONNECTIONS .............................................................. 8
OVERVIEW ..........................................................................................9
OPERATION .........................................................................................10
MAINTENANCE ...................................................................................12
FAULT FINDING ................................................................................... 13
COMPONENT PARTS ...........................................................................14
CONSUMABLE SPARES........................................................................16
SPECIFICATION ...................................................................................16
VIBRATION EMISSIONS .......................................................................17
DECLARATION OF CONFORMITY.......................................................19

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GENERAL SAFETY RULES
WORK AREA
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, gasses or dust. Power tools create sparks
which may ignite dust or fumes.
3. Keep children and bystanders away while operating a power tool.
Distractions can cause you to loose control.
ELECTRICAL SAFETY
1. Power tools must match the power outlet. Never modify the plug in any
way. Do not use adaptor plugs with earthed (grounded) power tools.
Correct plugs and outlets will reduce the risk of electric shock.
2. Do not expose power tools to rain or wet conditions. Any water entering
power tools will increase the risk of electric shock.
3. Do not abuse the electrical cable. Never use the cord for pulling or un-
plugging the power tool. Keep the cable away from sources of heat, oil,
sharp edges or moving parts. Damaged or tangled cables increase the
risk of electric shock.
4. When operating a power tool outdoors, use an extension cable suitable
for outdoor use. Using the correct cable reduces the risk of electric shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when you
are operating a power tool. Do not operate a power tool when you are
tired, ill or under the influence of alcohol, drugs or medication.
2. Wear personal protective equipment including eye protection. Safety
equipment such as a dust mask, non-skid shoes or hearing protection used
for appropriate conditions will reduce personal injuries. Use a face or dust
mask if operation is particularly dusty. Wear ear protectors/defenders as
the noise level of this machine can exceed 85dB (A). If working at floor
level, always wear knee pads.
3. Do not over-reach. Keep your proper footing and balance at all times. This
enables better control of the power tool in unexpected situations.
4. Avoid accidental starting of the machine. Ensure the switch is in the off
position and the locking button disengaged before plugging the machine
in to the power supply. Carrying power tools around with your finger on
the trigger or plugging in power tools that are switched on invites
accidents.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
5. Dress properly. Do not wear loose clothing or jewellery which may get
caught in moving parts. Wear protective hair covering to contain long
hair. For best footing, wear rubber soled footwear. Keep floor clear of oil,
scrap wood, etc.
6. Concentrate on the job in hand, no matter how trivial it may seem. Be
aware that accidents are caused by carelessness due to familiarity.
7. Switch the machine OFF immediately after the task is completed.
POWER TOOL USE AND CARE
1. Do not force the machine. Use the correct power tool for your application.
It will do a better and safer job at the rate for which it was designed.
2. Do not use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and
must be repaired.
3. Disconnect the power tool from the power supply before making any
adjustments, changing accessories, or storing the tool. These measures will
reduce the risk of the power tool starting accidentally.
4. Store power tools out of the reach of children and do not allow persons
unfamiliar with these instructions to operate the power tool. Power tools
are potentially dangerous in the hands of untrained users.
5. Maintain power tools in top condition. Keep tools/ machines clean for the
best and safest performance. Check for misalignment or binding of
moving parts, broken parts, or any condition that may affect the power
tool’s operation. If damaged, have the power tool repaired before use.
Many accidents are caused by poorly maintained power tools.
6. Use recommended accessories. The use of improper accessories could be
hazardous.
7. Machine cleanliness. Do not allow the ventilation slots in the machine to
become blocked with dust.
8. Check the power tool for damage before using the machine. Any
damaged part should be inspected to ensure that it will operate properly
and perform its intended function. Check for alignment of moving parts,
breakage of parts, mountings, and any other condition that may affect
the machine’s operation. Any damage should be properly repaired or the
part replaced. If in doubt, DO NOT use the machine. Consult your local
dealer.
SERVICE
1. When necessary, have your power tools serviced or repaired by a
qualified person using identical replacement parts. This will ensure that the
safety of the power tool is maintained.

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ANGLE GRINDER SAFETY INSTRUCTIONS
1. Before starting work, always consider that 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. 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.
3. Always allow the angle grinder to run up to full operating speed before
applying it to the job.
4. Stop the angle grinder at regular intervals for a short break to rest hands
and arms.
5. Never bump the angle grinder disc on the workpiece, or let the disc hit
any other objects while grinding.
6. Suitable eye and face protection must be worn when using an angle
grinder. Always wear a dust mask.
7. 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. Use clamps or vices to hold the workpiece. Failure to secure the
workpiece could result in serious injury.
9. Keep all handles and grips dry and clean.
10. If working outdoors, always use an approved cable extension suitable for
the power rating of this tool (see specifications), the conductor size should
also be at least the same size as that on the machine, or larger. When
using a cable reel, always unwind the cable completely. We strongly
recommend that this machine is connected to the mains supply via a
Residual Current Device (RCD).
11. Keep the mains cable well away from the disc and ensure an adequate
electrical supply is close at hand so that the operation is not restricted by
the length of the cable.
12. A guard or other part that is 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.
13. Ensure all wheels and discs are fitted in accordance with the instructions.
14. Ensure that sparks and particles resulting from grinding do not create a
hazard, Use screens where appropriate.
15. When 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.
16. Do not operate the spindle lock while the spindle is still spinning.

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17. Do not use the angle grinder without the disc guard. Make sure that the
guard is securely fitted before operating the angle grinder.
18. 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.
19. For cutting, always feed the disc into the work so that an upcutting action
is achieved.
20. Do not allow bystanders (children or adults) to be nearby when using an
angle grinder.
DISC SAFETY INSTRUCTIONS
1. Check the speed of the disc before fitting. Never use a disc with a rated
speed less than the no load speed of your angle grinder and only use
discs that comply with EN12413. See Specifications on page 16. Check
that the speed marked on the wheel dimensions is compatible with the
grinder. Check that discs are specifically for hand held angle grinder use.
2. Inspect the disc carefully before use. Never use a disc that is chipped,
cracked or damaged. Fragments from a broken or damaged disc can
cause serious injury. Ensure defective discs are destroyed and not used.
3. Bonded abrasive products are breakable and must therefore be handled
with utmost care. The use of damaged or improperly mounted or used
abrasive products is dangerous and can cause serious injuries.
4. 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.
5. Always use the correct disc for it’s intended task. Using the incorrect disc
can cause serious injury.
6. 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.
7. Do not use cutting discs for side grinding. Do not put sideways pressure on
cutting discs.
8. 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.
9. 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. It is
recommended that discs are stored in the case provided to protect them
from damage and hazardous material.
Please keep these instructions in a safe place for future reference.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
ELECTRICAL CONNECTIONS
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
Before switching the product on, make sure that the voltage of your electric-
ity supply is the same as that indicated on the rating plate. This product is
designed to operate on 230VAC 50Hz. Do not connect it to any other power
source.
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 re-
placement 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.
WARNING! The wires in the power cable of this product are
coloured in accordance with the following code:
Blue = Neutral Brown = Live
If the colours of the wires in the power cable of this product do not corre-
spond with the terminal markings of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal which
is marked Nor coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked Lor coloured Red.
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Neutral Live
(Blue) (Brown)
Ensure that the outer sheath of the cable is firmly held by the clamp
We strongly recommend that this productis connected to the mains supply
via a Residual Current Device (RCD).
If in doubt, consult a qualified electrician. DO NOT attempt repairs yourself.
This symbol indicates that this is a Class II product and does not require
an earth connection.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
OVERVIEW
When unpacking, check for damage or shortages etc. Any found should be
reported to your CLARKE dealer where the appliance was originally
purchased. This CAG900 Angle Grinder is supplied with the following
components:
• 1 x Disc Guard
• 1 x Grinding Disc
•1 x Pin Spanner
•1 x Side Handle
•Pair Carbon Brushes
6
1
5
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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
BEFORE USE
FITTING / ADJUSTING THE DISC GUARD
Slide the disc guard over the end of
the grinder.
Rotate the guard to the required
position and secure by tightening the
screw into the square nut until the
guard is clamped in place.
The guard should be fitted to give
maximum protection from the disc
when fitted in the working position.
FITTING/REMOVING THE DISC
Ensure the disc guard is correctly fitted before installing the disc.
WARNING: MAKE SURE THAT THE GRINDER IS SWITCHED OFF AND
UNPLUGGED FROM THE MAINS SUPPLY BEFORE FITTING OR REMOVING
THE DISC.
1. Press and hold the spindle lock
button.
• You may need to turn the spindle
by hand to fully engage the
spindle lock.
2. Use the pin spanner supplied to
loosen & remove the outer flange.
3. Ensure that the inner flange is
fitted correctly with the raised flat
surfaces pointing inwards as
shown to engage with the flat
section on the spindle.
4. Place the grinding disc over the spindle to sit on the inner flange.
• If the grinding wheel supplied is a ‘Depressed Centre’type, mount it as
shown, i.e. with the depressed centre towards the machine.
• For standard discs ensure the raised section of the outer flange is pointing
towards the disc.
5. Screw on the outer flange with the centre boss facing inwards so as to sit
inside the apperture of the disc. Tighten securely with the pin spanner.
• When using thin discs, the outer flange can be reversed so that the raised
section is pointing away from the disc.
Disc Outer flange
pin spanner
Raised surface
of inner flange

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
6. Press and hold the spindle lock and use the pin spanner to tighten the
outer flange. Care should be taken also NOT to overtighten.
FITTING THE SIDE HANDLE
1. Fit the side handle by screwing it
into the threaded hole on either
the left or right hand side of the
angle grinder.
OPERATION
WARNING: FRAGMENTS FROM A BROKEN/DETACHED DISC CAN CAUSE
SERIOUS INJURY. ALWAYS WEAR SUITABLE EYE AND FACE PROTECTION.
WARNING: WHEN USING CUTTING DISCS, 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 LEADING TO LOSS OF CONTROL OF THE
CUTTING DISC. ALWAYS WEAR EYE PROTECTION.
WARNING: ENSURE THE INTENDED CUTTING PATH IS CLEAR AND WITH
SUFFICIENT CLEARANCE BETWEEN SURROUNDING OBJECTS.
WARNING: WHEN CUTTING, KEEP THE ANGLE GRINDER STRAIGHT TO
PREVENT SNATCHING OR JAMMING.
THE ON/OFF SWITCH
1. To start the angle grinder, slide the
trigger forwards while pressing the
heel of the button towards the
tool body.
• The grinder will start instantly.
Ensure a firm grip is maintained
with both hands.
2. To stop the angle grinder, release
the trigger.
WARNING: THE DISC WILL CONTINUE TO ROTATE FOR A FEW SECONDS
AFTER THE TRIGGER HAS BEEN RELEASED.

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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.
• Whenever a new disc has been fitted, always run the grinder at no load
speed to check for irregularities before beginning work.
GRINDING TIPS
WARNING: WHEN GRINDING, ONLY USE DISCS SPECIFICALLY DESIGNED
FOR GRINDING. YOU MUST NEVER USE CUTTING DISCS TO GRIND ANY
MATERIAL.
• 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.
MAINTENANCE
Before commencing any maintenance procedures, always ensure the
grinder is isolated from the electrical supply by switching off and removing
the plug from the power socket.
BEFORE USE
1. Always inspect the tool before use and ensure it is in top condition.
2. Ensure all fixing screws remain tight to ensure the grinder is in safe working
condition.
3. Ensure the grinding wheel or cutting disc is perfectly sound, free from
cracks or damage.
4. Inspect the power cable to ensure it is sound and free from cracks or bare
wires etc.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
FAULT FINDING
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CLEANING
1. Ensure all air ventilation slots are clear. Use compressed air to clean the
machine if possible. (Always wear protective goggles when cleaning with
compressed air).
2. Clean the exterior of the machine with a soft cleaning cloth. Never use
any chemicals or harsh abrasives. Avoid using solvents when cleaning
plastic parts, which may be susceptible to damage from various types of
commercial solvents.
GENERAL MAINTENANCE
• All bearings etc, in this tool are lubricated with a sufficient amount
of high grade lubricant for the tools lifetime under normal
operating conditions, therefore no further lubrication is necessary.
• Refer to your CLARKE dealer if internal maintenance is required.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
COMPONENT PARTS

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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COMPONENT PARTS

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
COMPONENT PARTS
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CONSUMABLE SPARE PARTS
Replacement cutting/grinding discs are available from your CLARKE dealer.
Refer to your Clarke dealer or service department if internal maintenance is
required.
Replacement abrasive, cutting, and grinding discs include:
Metal Grinding Discs: 115 mm dia Part No: 6470705
Metal Cutting Discs: 115 mm dia Part No: 6470775
Masonry Cutting Discs: 115 mm dia Part No: 6470735
Plasma Fine Cut Cutting Discs: (Model PD1) 115 mm dia Part No: 3052050
SPECIFICATION
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Please note that the details and specifications contained herein, are correct at the
time of going to print. However, CLARKE International reserve the right to change
specifications at any time without prior notice.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
VIBRATION EMISSIONS
MODEL No: CAG900
DESCRIPTION: 900W ANGLE GRINDER
Declared vibration emission value in accordance
with EN12096
Measured vibration emission value - a: 7.35m/s2
Values determined according to EN28622-1
Employers are advised to refer to the HSE publication “Guide for Employers”.
All hand held power tools vibrate to some extent, and this vibration is transmit-
ted to the operator via the handle, or hand used to steady the tool. Vibration
from about 2 to 1500 Hertz is potentially damaging and is most hazardous in
the range from about 5 to 20 Hertz.
Operators who are regularly exposed to vibration may suffer from Hand Arm
Vibration Syndrome (HAVS), which includes ‘dead hand’, ‘dead finger’, and
‘white finger’. These are painful conditions and are widespread in industries
where vibrating tools are used.
The health risk depends upon the vibration level and the length of time of
exposure to it……in effect, a daily vibration dose.
Tools are tested using specialised equipment, to approximate the vibration
level generated under normal, acceptable operating conditions for the tool
in question. For example, a grinder used at 45° on mild steel plate, or a
sander on softwood in a horizontal plane etc.
These tests produce a value‘
a’ , expressed in metres per second per second,
which represents the average vibration level of all tests taken, in three axes
where necessary, and a second figure ‘K’, which represents the uncertainty
factor, i.e. a value in excess of ‘a’, to which the tool could vibrate under
normal conditions. These values appear in the specification panel below.
HAND-ARM VIBRATION

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You will note that a third value is given in the specification - the highest
measured reading in a single plane. This is the maximum level of vibration
measured during testing in one of the axes, and this should also be taken into
account when making a risk assessment.
‘
a ’ values in excess of 2.5 m/s2are considered hazardous when used for
prolonged periods. A tool with a vibration value of 2.8 m/s2may be used for
up to 8 hours (cumulative) per day, whereas a tool with a value of 11.2 m/s2
may be used for ½ hour per day only.
The graph below shows the vibration value against the maximum time the
respective tool may be used, per day.
The uncertainty factor should also be taken into account when assessing a
risk. The two figures ‘ a ’ and ‘ K ’may be added together and the resultant
value used to assess the risk.
It should be noted that if a tool is used under abnormal, or unusual conditions,
then the vibration level could possibly increase significantly. Users must
always take this into account and make their own risk assessment, using the
graph above as a reference.
Some tools with a high vibration value, such as impact wrenches, are gener-
ally used for a few seconds at a time, therefore the cumulative time may only
be in the order of a few minutes per day. Nevertheless, the cumulative
effect, particularly when added to that of other hand held power tools that
may be used, must always be taken into account when the total daily dose
rate is determined.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
DECLARATION OF CONFORMITY