Clarke METALWORKER CAG121 Installation and operation manual

4½ ” Angle Grinder
Model CAG121
0504
Part Number 6470088
Operating & Maintenance
Instructions
©

Parts and Service
For Spare Parts and Servicing, please contact your local dealer, or
Clarke International on one of the following Numbers:
Parts and Service Tel: [phone]
Parts and Service Fax: [phone]
or email as follows:
Parts: [email protected]
Service: [email protected]
j
If you have any problems using or setting up your Grinder call
the Clarke Helpline on :
020 89887400
Press 1 for Parts : 2 for Technical Assistance

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Contents
Guarantee ........................................................................................................ 2
Features and Use ............................................................................................ 2
For your Own Safety......................................................................................... 3
General Safety Precautions : For Power Tools .............................................. 3
Safety Precautions : For Angle Grinders ........................................................ 4
Electrical Connections .................................................................................... 5
Overview of your Angle Grinder .................................................................... 6
Mounting the Grinding Wheel / Cutting Disc ................................................ 7
Maintenance .................................................................................................... 8
Troubleshooting ................................................................................................ 9
Specification .................................................................................................... 9
Spare Parts Diagram ........................................................................................ 10
Spare Parts List .................................................................................................. 10
Recommended Grinding Wheels / Cutting Discs......................................... 10
Thank you for purchasing this Clarke Angle Grinder. Before using please read
these instructions. This is for your own safety and that of others around you, and to
help you achieve long and trouble free service from the Grinder.
Guarantee
This product is guaranteed against faults in manufacture for 12 months from
purchase date. Keep your receipt as proof of purchase.
This guarantee is invalid if the product has been abused or tampered with in
any way, or not used for the purpose for which it is intended. The reason for return
must be clearly stated. This guarantee does not affect your statutory rights.
Features and Use
This Angle grinder is a hand held power tool that uses abrasive disks to grind
metals or masonry. It is intended for D.I.Y and light commercial use. The grinder
features an adjustable guard, a spindle lock and removable handle grip that
make it easy to set up and use.

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Always keep work area clean and
clear. Cluttered areas and benches invite
accidents.
Always wear proper apparel. Loose
clothing or jewellery may get caught in
moving parts. Wear protective hair covering
to contain long hair.
Always handle equipment with care.
Do Not carry the tool by its’ electric cable,
or yank the cable to disconnect it from
the power supply.
Always ensure the switch is OFF before
plugging in to mains. This will ensure the
equipment does not start accidentally.
Always follow the maintenance
instructions. Keep tools clean and maintained
for the best and safest performance.
Never force the tool. It will do a better
and safer job at the rate for which it was
designed.
Never operate equipment while under
the influence of Drugs, Alcohol or any
Medication.
Do Not overreach. Keep your proper
footing/balance at all times. For best footing
wear rubber soled footwear. Keep floor clear
of oil, scrap wood, etc.
Only Use recommended accessories.
The use of improper accessories could be
hazardous
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.
Keep children away when using Power Tools.
Eye protection manufactured to the current European Safety Standard
should be worn when using Power Tools.
For Your Own Safety
Always 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.
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.
Always wear safety goggles
manufactured to the latest European Safety
Standards, everyday eyeglasses do not have
impact resistant lenses, they are NOT safety
glasses.
Always use a face or dust mask if
operation is particularly dusty.
Always disconnect the tool from the
power supply before servicing and when
changing accessories.
Always use in a suitable 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
explosive atmosphere. (i.e near flamable liquids etc.).
General Safety Precautions : For Power Tools

Eye Protection manufactured to the current European Safety Standard should be
worn when operating grinding equipment.
Ear Protection manufactured to the current European Safety Standard should be
worn when operating grinding equipment.
A Dust Mask manufactured to the current European Safety Standard should be worn
when operating grinding equipment.
WARNING ! Ensure all accessories used are rated a the spindle speed, or higher.
WARNING ! Never press the spindle lock while the disc is rotating.
Additional Safety Precautions : For Angle Grinders
15 - 30O
(1) (2)
Always wear a good pair of industrial
gloves to avoid potential injury from sparks
and debris .
Always keep the mains cable well away
from the tool. Ensure an adequate electrical
supply is close at hand so that the operation
is not restricted by the length of the cable.
Always switch the tool OFF immediately
when the task is completed.
Always ensure the grinding wheel or
cutting disc is fully tightened before use.
Always ensure the wheel / disc is not
touching the work when switching ON.
Always allow the Grinder to run briefly
before using. Check for vibration which could
indicate poor balance or installation of the
wheel/disc.
Always hold the tool firmly in BOTH
hands (as shown in figure (1)).
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
pressurecan cause dangerous disc breakage
and/or damage to the tool.
Never allow the ventilation slots in the
tool to become blocked.
Never use the tool with the guard
removed. If the guard becomes damaged,
it should be replaced
Never use the tool in a confined space
which may limit body movement.
Use only wheels/discs designed for their
specific function.(see page 10)
Beware of flying sparks. Hold the grinder at
an angle of 15 - 30Oto the workpiece
surface(as shown in figure (2)).
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IMPORTANT: If this appliance is fitted with a plug which is moulded on to the electric
cable (i.e. non- re-wireable) 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.
5. The fuse in the plug must be replaced with one of the same rating (13 amps)
and this replacement must be ASTA approved to BS1362.
IMPORTANT: If in any doubt, do not attempt any electrical repair yourself. Consult a
qualified technician
Double Insulated Electrical Appliance
This appliance is of Double Insulation Construction. Because of its construction there is no
earth required and therefore there is no Earth connection.
Connect the mains lead to a standard 230V (50Hz) electrical supply through an approved
13 Amp BS1363 plug, or a suitably fused isolator switch.
The two wires in the mains lead should be wired up in accordance with the following colour
code:
IMPORTANT : The wires in the mains lead are coloured in accordance with the following code:
Blue - Neutral
Brown - Live
As the colours of the flexible cord of this appliance may not correspond with the coloured
markings identifying terminals in your plug proceed as follows:
Connect BROWN coloured cord to plug terminal marked with a letter L or coloured RED
Connect BLUE coloured cord to plug terminal marked with a letter Nor coloured Black
Electrical Connections
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Before Using the Grinder
Fit the Handle :Screw the handle (4) into the left or right hand position in the grinder
head as required.
Mount the Grinding Wheel / Cutting Disc : See page 7 ( i ) for details
Adjust the Guard : The guard (3) needs to be adjusted to give maximum protection
from sparks and debris produced when grinding. Slacken the Hex Socket head screw
securing the guard and rotate into position, then retighten the screw.
Connectting to the Power Supply : Connect to the power supply using a Residual Current
Device. Do not use in wet or damp conditions.
WARNING ! Ensure that the power supply is disconnected before adjusting the guard or
mounting the handle.
1
3 4
5
2
6
1 Safety ON/OFF Switch
2 Spindle Lock Button
3 Adjustable Guard
4 Handle
5 Abrasive Disk
6 Body
Figure (1) Overview
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Unscrew and remove the outer flange :
If it is tight, lock the spindle by pressing
the Spindle Lock button and use the tool
supplied to turn the flange to break the
seal. It may then be screwed off by
hand.
Mount the Grinding Wheel : as shown in
the diagram. The Grinding wheel
supplied is a Depressed Centre’ type.
Mount with the depressed centre
towards the motor.
Screw on the Outer Flange : with the
centre boss facing inwards ensuring the
wheel sits snugly over the raised boss on
the inner flange.Tighten the flange using
the tool provided, locking the spindle by
pressing the Spindle Lock button, and
taking care to ensure the wheel is still
sitting snugly, centred over the flange
bosses. Do Not over-tighten the outer
flange.
Mounting the Grinding Wheel / Cutting Disc
( i )
IMPORTANT ! Fig (2) shows the set up for a grinding wheel.
WHEN ATTACHING A CUTTING DISC YOU MUST REVERSE THE OUTER FLANGE
Figure (2) Mounting Discs
1
2
3
Using the Grinder
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.
Hold the Grinder firmly in both hands. The hand holding the body will control the ON/
OFF switch, whilst the other hand grasps the handle and guides the tool over the
workpiece. Hold at 15 - 300 from the workpiece.
To Start the Motor press the switch to “I”. To Stop the Motor press the switch to “0”.
Allow the tool to do the work, do not force the wheel on to the workpiece.
IMPORTANT! BE AWARE at all times, the tool can be very dangerous if not used properly
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Maintenance
IMPORTANT! Ensure that the grinder is disconnected from the power supply before
carrying out any maintenance.
Always inspect the tool before use, and ensure it is in top condition.
Ensure all air vents are clear, use compressed air to clean the tool where possible.
(Always wear protective goggles when cleaning with compressed air).
Check the power cable to ensure it is sound and not damaged in any way.
Ensure the grinding wheel or cutting disc is perfectly sound and free from cracks or
damage in any way.
After every 50 hours of use the motors carbon brushes need to be checked and
renewed if nessessary. You will need a cross head screwdriver and a small flat head
screwdriver. The brushes are changed as follows :
Before Each Use
After Every 50 Hours of use
A
BC
1 Unscrew the casing screw (A) and pull the casing
away from the body by sliding casing down the
power lead to give access to motor brushes.
2 Remove the brush assembly by unclipping with a
flat head screwdriver. (B)
3If the brush is worn (less than 6mm left, see (C)) then
replace the brush assembly by clipping a new one
into place (D). Replace the casing and secure with
the casing screw takingcare not to damage the Lead.
D
Casing Screw
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Troubleshooting
Problem Possible Cause Repair
Tool will not operate 1. No supply 1. Check supply and rectify
where necessary.
2. Switch is faulty 2. Consult your Clarke dealer
3. Brushes badly worn 3. Check and replace if necessary
4. Fuse blown 4. Check and replace if necessary
If condition persists, consult your
dealer
5. Motor faulty 5. Consult your Clarke dealer.
Motor runs but disc 1. Flange nut not tight 1. Tighten flange nut
does not turn 2. Gear shaft or key 2. Consult your Clarke dealer
broken
Heavy internal 1. Faulty motor 1. Consult your Clarke dealer
sparking 2. Badly worn brushes 2. Renew brushes (see p.8)
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. Disc not mounted 1. Check and rectify
correctly or is damaged
2. Bearings worn 2. Consult your Clarke dealer
Specification
Model No ................................................................. CAG 121
Part No ..................................................................... 6470088
Supply Voltage ........................................................ 230 V AC, 50 Hz, 1 Phase
Fuse Rating .............................................................. 13A
Insulation Class ........................................................ E
No Load Speed ....................................................... 11,000 RPM
Maximum Cutting Wheel Diameter ..................... 115mm
Cutting Wheel Bore................................................. 22mm
Drive Spindle Thread ............................................... M14
Tool Weight .............................................................. 1.6kg
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