Clarke CON115 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
4½” (115mm)
ANGLE GRINDER
Model No. CON115
4½” (115mm)
ANGLE GRINDER
GC0911

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SPECIFICATIONS
Motor ............................................................. 230V~ 50Hz 1ph
Power Rating ................................................. 1010Watts
Fuse Rating .................................................... 13Amps
No Load Speed ............................................. 11,000RPM
Wheel/Disc Dia. ............................................ 115mm
Bore ................................................................ 22mm
Sound Power Level ....................................... 103dBL
WA
Sound Pressure Level ................................... 89.9dBL WA
Vibration Level .............................................. 2.7m/s2
Weight (Net) .................................................. 2.7kg
Part No. .......................................................... 6470140
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.

Thank you for selecting this CLARKE 115mm (4½”) Angle Grinder.
Before attempting to use the tool, please read this leaflet 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 the Angle Grinder 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 therefore, 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.
CONTENTS
Specifications ............................................................................... 2
Safety Precautions ....................................................................... 3
Additional Precautions for Angle Grinders ................................ 5
Electrical Connections ................................................................ 6
Features ........................................................................................ 7
Assembly ....................................................................................... 7
Operation ..................................................................................... 8
Maintenance ............................................................................... 8
Troubleshootiing ........................................................................... 9
Spare Parts & Service Contacts ................................................. 9
Spare Parts ................................................................................. 10
Declaration of Conformity ........................................................ 11
GENERAL SAFETY PRECAUTIONS
WARNING:
As with all machinery, there are certain hazards involved with their operation
and use. Exercising respect and caution will considerably lessen the risk of
personal injury. However, if normal safety precautions are overlooked or
ignored, personal injury to the operator or damage to property, may result.
1. READ and BECOME FAMILIAR with the entire operating manual. Learn the
tool’s applications, limitations and the specific potential hazards peculiar to it.
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2. ALWAYS ensure that ADEQUATE LIGHTING is available. A minimum intensity of
300 lux should be provided. Ensure that lighting is placed so that you will not
be working in your own shadow.
3. CHECK FOR DAMAGE. Before using the tool, any damaged part should be
checked 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 tools’ operation. Any damage
should be properly repaired or the part replaced. If in doubt, DO NOT USE the
tool. Consult your local dealer.
4. DISCONNECT THE TOOL from the power supply before servicing and when
changing accessories.
5. ALWAYS WEAR SAFETY GOGGLES manufactured to the latest European Safety
Standards. Everyday eyeglasses do not have impact resistant lenses, and are
NOT safety glasses.
6. KEEP WORK AREA CLEAN. Cluttered work areas and benches invite accidents.
7. DON’T FORCE the tool. It will do a better and safer job at the rate for which it
was designed.
8. ALWAYS use a face or dust mask if operation is particularly dusty.
9. DRUGS, ALCOHOL & MEDICATION. Do not operate tool while under the
influence of drugs, alcohol or any medication.
10. USE RECOMMENDED ACCESSORIES. The use of improper accessories could
be hazardous.
11. NEVER LEAVE THE TOOL RUNNING UNATTENDED. Turn power OFF. Do not leave
the tool until it comes to a complete stop.
12. AVOID DANGEROUS ENVIRONMENT. Don’t use power tools in damp or wet
locations or expose them to rain. Keep your work area well illuminated.
DO NOT USE in an explosive atmosphere (near paint, flammable liquids etc).
13. KEEP CHILDREN AWAY. All visitors should be kept a safe distance from the work
area, especially whilst operating the tool.
14. MAINTAIN TOOL IN TOP CONDITION. Keep tools clean for the best and safest
performance. Follow maintenance instructions.
15. DON’T OVERREACH. Keep your proper footing/balance at all times. For best
footing wear rubber soled footwear. Keep floor clear of oil, scrap wood, etc.
16. WEAR PROPER APPAREL. Loose clothing or jewellery may get caught in moving
parts. Wear protective hair covering to contain long hair.
17. HANDLE WITH EXTREME CARE Do Not carry the tool by its electric cable, or
yank the cable to disconnect it from the power supply.
18. AVOID ACCIDENTAL STARTING. Ensure the switch is OFF before plugging into mains.
19. BE AWARE that accidents are caused by carelessness due to familiarity.
ALWAYS concentrate on the job in hand, no matter how trivial it may seem.
20 Guard against electric shock. Avoid body contact with earthed or grounded
surfaces (e.g. Pipes, Radiators, Ranges, Refrigerators).

ADDITIONAL PRECAUTIONS FOR ANGLE GRINDERS
1. It is strongly advised that you wear ear protectors/defenders as the noise level
during operation, depending upon the work being carried out, can exceed
safe working levels.
2. Always wear a good pair of industrial gloves to avoid potential injury from
sparks and debris.
3. Do not use the tool if the electric cable, plug or motor is in poor condition.
4. Keep the mains cable well away from the tool and ensure an adequate electrical
supply is close at hand so that the operation is not restricted by the length of the cable.
5. Switch the tool OFF immediately the task is completed.
6. Never allow the ventilation slots in the tool to become blocked.
7. Do not attempt any electrical repair yourself. Consult a qualified electrician, or
the Clarke Service Department on 0208 988 7400.
8. DO NOT cut through walls or cavities before checking for hidden electrical
wires or water pipes etc.
9. Ensure the grinding wheel or cutting disc is fully tightened before use.
10. Do not use the tool in a confined space which may limit body movement.
11. Ensure the wheel/disc is not touching the work when switching ON.
12. Use only wheels/discs having a maximum operating speed of at least 11,000RPM.
13. Check the disc carefully for cracks or damage before operation. Replace
cracked or damaged wheels/discs immediately.
14. Take care not to damage the spindle or wheel flanges as damage to these
parts could result in wheel/disc breakage.
15. ALWAYS hold the tool firmly in BOTH hands.
16. Before using the tool on an actual workpiece, allow it to run briefly, checking for
vibration which could indicate poor balance or installation of the wheel/ disc.
17. Use only wheels/discs designed for their specific function. DO NOT use cutting
discs for grinding metal, or metal grinding wheels for cutting masonry.
18. When grinding, hold the grinder at an angle of 15-30Oto the work surface.
19. NEVER use excessive force. It should only be necessary to use a little more than
the weight of the tool. If the rotational speed drops abnormally, reduce pressure
immediately. Forcing the tool and excessive pressure can cause dangerous
disc breakage and/or damage to the tool.
20. NEVER use the tool with the guard removed. If the guard becomes damaged,
it should be replaced.
21. NEVER twist the grinder when using Cutting Discs. Take care to ensure sparks
do not fall on to sensitive areas. Be aware of the fire risk from sparks.
22. Never use Wheels/Discs other than 115mm diameter.
23. ALWAYS store and handle abrasive discs according to the manufacturer’s
instructions. 5

ELECTRICAL CONNECTIONS
This product is provided with a 13 amp, 230 volt (50Hz), BS 1363 plug, for connection
to a standard, domestic electrical supply. Should the plug need changing at any
time, ensure that a plug of identical specification is used.
WARNING!
This appliance is of Double Insulation construction
No earth conductor is provided. The two wires in the mains lead should be wired
up in accordance with the following colour code:
Blue — Neutral
Brown — Live
Connect the BROWN coloured cord to the plug terminal marked a letter “L”
Connect the BLUE coloured cord to the plug terminal marked a letter “N”
If this appliance is fitted with a plug which is moulded on to the electric cable (i.e.
non-rewireable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code).
4. Replacement fuse covers can be obtained from your local dealer or most
electrical stockists.
Fuse Rating
The fuse in the plug must be replaced with one of the same rating (13 amps) and
this replacement must be approved to BS1362.
If in doubt, consult a qualified electrician. Do not attempt any electrical repairs yourself.
Cable Extension
Do not use an extension longer than 10 metres and one where the conductors, are
less than 1.5mm2.
If used outdoors, ensure the extension cable is designed for outdoor use.
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24. NEVER use a cutting-off wheel for side grinding.
25. ALWAYS ensure the work is properly secured or supported.
26. Do not allow flying sparks to fall on sensitive areas. Be aware of fire risks.
27. When not in use always store in a dry clean environment and out of reach of
children.
Additionally, ALWAYS keep these instructions in a safe place for future reference.

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WARNING:
NEVER press the spindle lock button when starting the tool, and
NEVER press the button when the tool is operating.
DO NOT press thebutton until the wheel/disc has stopped completely
ASSEMBLY
1. Mounting the Grinding Wheel/Cutting Disc
Fig 1.
FEATURES (Ref. Fig 1)
1.1 Unscrew and remove the outer flange by locking
the spindle using the Spindle Lock button then
usethe flange tool supplied to turn the flange (right
hand thread). It may then be screwed off by
hand.
1.2 The grinding wheel supplied is the ‘Depressed
Centre’type. Mount it as shown in the Fig.2. i.e.
with the depressed centre towards the motor
1.3 Ensuring the wheel sits snugly over the raised boss on
the inner flange, screw on the outer flange with the
centre boss facing inwards.
1.4 Tighten the flange using the tool provided, locking
the spindle by pressing the Spindle Lock button,
andtaking care to ensure the wheel is still sitting
snugly,centred over the flange bosses. Care should
be taken also NOT to overtighten the outer flange.
1. ON/OFF Switch (A)
The ON/OFF switch (A) is provided with a safety
lock button (B). The lock button (B) must be
held in before the trigger can be squeezed in
to the ‘ON’ position. This is designed to prevent
accidental starting.
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2. Spindle Lock Button (C)
WARNING:
Fig 2 shows the set up for a grinding wheel.
When attaching a cutting or diamond disc YOU MUST REVERSE the outer
flange so that the boss faces OUTWARDS.
Ensure the grinder is disconnected from the mains supply.
Fig 1.
Fig 2.
When pressed, this button, located on top
of the head, is used to lock the spindle
when attempting to unscrew and remove the outer flange (using the special tool
provided), in order to mount or change the grinding wheel or cutting disc.

The blade guard can be rotated about its axis
and is locked by a single hex head screw (see
Fig.3). Slacken the screw, using the tool supplied,
grasp the guard firmly and move to the desired
position, ensuring maximum protection for the
operator without impeding the work being
carried out. The screw must be tightened when
the guard is in the desired position.
NOTE: When the tool is new, it may be necessary
to slacken the three cross head screws, in
addition to the securing screw, in order to free
off the guard. This can only be achieved with
the cutting disc removed. Once the guard has
been moved, the three screws must be retightened, and should not require slackening
for this purpose again. Before fitting the cutting disc, try moving the guard again ensuring
only the locking screw is loose, then with the guard in the desired position, retighten the
locking screw.
The hand holding the tool body will control the ON/OFF trigger switch, whilst the other
hand grasps the hand grip and guides the tool over the workpiece.
Hold the tool firmly but not tightly. Allow the tool to do the work...DO NOT force the wheel
on to the workpiece.
The ON/OFF trigger switch (A) in Fig 1, is provided with a safety lock button (B), to
prevent accidental starting. To operate, fully depress the trigger switch and depressing
the safety lock button (B). To stop, release the lock button, and the trigger switch. The
grinder will slow down and stop.
MAINTENANCE
IMPORTANT: Before carrying out any maintenance tasks, ALWAYS disconnect the tool
from the mains electrical supply.
Before Each Use
1. Always inspect the tool before use and ensure it is in top condition.
2. Ensure all air vents are clear, use compressed air to clean the tool where possible.
(Always wear protective goggles when cleaning with compressed air.). Take all necessary
precautions regarding the use of compressed air.
3. Check the power cable to ensure it is sound and free from cracks, bare wires etc.
4. Ensure the grinding wheel or cutting disc is perfectly sound, free from cracks or damage
in any way.
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OPERATION
IMPORTANT: DO NOT plug the tool in to the mains, unless you have ensured it is switched
OFF and the guard is set to the desired position.
2.Hand Grip
A threaded hole ‘E’, on the top, left or right hand side of the gear housing, is provided so
that the hand grip may be screwed in, as required, to provide left or right hand control
of the tool.
Fig 3.
Whenever changing discs, always run the grinder at no load speed to check for
irregularities before beginning work.

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TROUBLESHOOTING
Problem Possible Cause Remedy
Tool will not operate 1. No supply 1. Check supply and rectify
where necessary.
2. Switch is faulty 2. Consult your Clarke dealer
3. Fuse blown 3. Check and replace if
necessary. If condition
persists, consult your dealer
4. Motor faulty 4. Consult your Clarke dealer.
Motor runs but disc 1. Flange nut not tight 1. Tighten flange nut
will not 2. Gear shaft or key 2. Consult your Clarke dealer
broken
Heavy internal 1. Faulty motor 1. Consult your Clarke dealer
Sparking
Motor gets hot 1. Work load too heavy 1. Reduce force applied to
tool
2. Low supply voltage 2. Ensure supply voltage is
correct. If extension cable is
used, ensure it is of the
correct value, and is fully
unreeled
Excessive vibration 1. Wheel not mounted 1. Check and rectify
correctly
2. Bearings worn 2. Consult your Clarke dealer
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
For Spare Parts and Service, please contact your nearest dealer,
or CLARKE International, on one of the following numbers.
SPARE PARTS AND SERVICE CONTACTS

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SPARE PARTS
1. Hand Grip HTCON11501
2. Guard HTCON11502
3. Friction Washer HTCON11503
4. Inner Flange HTCON11504
5. Grinding Wheel/Cutting Disc (See below)
6. Outer Flange HTCON11506
7. Guard Securing Screw HTCON11507
8. Guard Locking Screw HTCON11508
- Flange Release Tool HTCON11509
The following Grinding Wheels/ Cutting Discs are available from your Clarke dealer.
1. Metal Grinding (DPC) 115mm x 6mm thickness Part No: 6470705
2. Metal Cutting (DPC) 115mm x 3mm thickness Part No: 6470775
3. Masonry Cutting (DPC) 115mm x 3mm thickness Part No: 6470735
PARTS DIAGRAM

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