Clarke METALWORKER CHDBG500 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0719 - ISS 1
BENCH GRINDER
MODEL NO: CHDBG500
PART NO: 6500535

2
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INTRODUCTION
Thank you for purchasing this CLARKE Bench 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.
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 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.
If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

3
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
SPECIFICATIONS
Model Number CHDBG500
Part Number 6500535
Dimensions (D x W x H) 466 x 194 x 254 mm
Weight 16.5 kg
Rated Voltage 230 V~ 50 Hz
Rated Input Wattage 500 W
No Load Speed 2850 RPM (+/- 5%)
Abrasive wheels supplied Coarse (36 Grit), Fine (60 Grit)
Wheel dimensions Diameter (150 mm) Thickness (25 mm) Bore
(32 mm)
Duty Cycle classification S2/30 minutes
Sound pressure 78 dB(A)
Sound power (measured) 97 dB LpA
Sound power (Guaranteed) 98 dB LwA
Uncertainty factor K 0.42 dB

4
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
POWER TOOL SAFETY WARNINGS
1) 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, 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. Distractions can
cause you to lose control.
2) 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. Water entering a power tool will
increase the risk of electric shock.
3. Do not abuse the power cable. Never use it for carrying, pulling or unplugging the
power tool. Keep the power 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.
5. If operating the power tool in a damp location is unavoidable, use a residual current
device (RCD) protected supply.
3) 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.
2. Use safety equipment. Always wear eye protection. Safety equipment such as dust
mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
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 wrench before turning the power tool on. A wrench left attached to a
rotating part 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.
6. Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and
gloves away from moving parts. Loose clothes, jewellery or long hair can be caught
in moving parts.

5
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
4) POWER TOOL USE AND CARE
1. Do not force the power tool. Use the correct accessories for your application. The
correct power tool will do the job better and safer at the rate 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 plug from the power source before changing accessories, or storing
power tools. Such preventive safety measures reduce the risk of starting the power
tool accidentally.
4. Store idle tools out of the reach of children and do not allow persons unfamiliar with
the power tool or these instructions to operate it. Power tools are dangerous in the
hands of untrained users.
5. Maintain power tools. Check for misalignment or binding of moving parts, breakage
of parts and any other 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 the power tool and accessories in accordance with these instructions and in the
manner intended, taking into account the working conditions and the work to be
performed. Use of the power tool for operations different from intended could result
in a hazardous situation.
7. The performance of this tool may vary, depending upon variations in line voltage.
Extension cable usage may also affect performance.
5) SERVICE
1. Have your power tool serviced by qualified service personnel using only identical
replacement parts. This will ensure that the safety of the power tool is maintained.
BENCH GRINDER SAFETY WARNINGS
1. Hold the tool or blade being sharpened firmly to prevent loss of control.
2. NEVER install a abrasive flap wheel or sanding disc on this grinder.
3. ALWAYS replace a cracked grinding wheel immediately.
4. NEVER use damaged or incorrect grindstones. The stone and retaining bolt
were specially designed for your grinder, for optimum performance and
safety of operation. Inspect the condition of the grinding stone before use
and do not use if any damage is noticed.
5. Do not use aluminium oxide wheels when grinding non-ferrous metals such
as aluminium or brass. Use silicon carbide wheels (not included) for grinding
non-ferrous metals.
6. ALWAYS use the rests to steady the workpiece. If the rests are not used, the
torque of the spinning grinding/polishing wheel may pull the workpiece
from your hands.

6
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
7. NEVER leave the grinder unattended when it is connected to an electrical
power supply. Switch off the grinder and unplug it before leaving.
8. ALWAYS check for damaged parts. Before further use of the tool, a guard
or other part that is damaged should be carefully checked to determine if
it would operate properly and perform its intended function. Check for
misalignment or binding of moving parts, breakage of parts and any other
condition that may affect the tool's operation. A part that is damaged
should be properly repaired or replaced at an authorised service centre.
Following this rule will reduce the risk of electric shock, fire or serious injury.
9. Gloves, manufactured to the current European safety standards should be
worn when operating grinding equipment.
10. Eye protection manufactured to the current European safety standards
should be worn when operating grinding equipment.
NOTE: Bench grinders used in industrial environments may be subject to the
requirements of The Provision and Use of Work Equipment regulations
1992 (particularly regarding the training requirement of The Abrasive
Wheels Regulations 1970) or other legislation. If in doubt seek advice.
Please keep these instructions in a safe place for future reference.
SAFETY SYMBOLS
Read instruction manual before use
This machine is not suitable for hand held use
Not permitted for wet grinding
Wear eye protection
Wear ear defenders
Wear protective gloves

7
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
ELECTRICAL CONNECTIONS
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved BS 1363 plug or a suitably fused isolator switch.
If the plug has to be changed because it is not suitable for your socket, or
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely, as
insertion into a power socket could cause an electrical hazard.
If the colours of the wires in the power cable do not agree with the markings
on the plug.
• Connect the BLUE wire
to the terminal
marked N.
• Connect the BROWN
wire to the terminal
marked L.
•ConnecttheYELLOW
AND GREEN wire to
the terminal marked E
or .
AN APPROVED RESIDUAL
CURRENT DEVICE (RCD) WHICH HAS A TRIPPING CURRENT OF LESS THAN 30 mA
MUST BE USED.
If you are not sure, consult a qualified electrician. DO NOT try to do any
repairs.
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 YELLOW AND GREEN = EARTH
Plug must be BS1363/A approved.
Always fit
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
Earth
(Green and
a 5 Amp
the cable is firmly held by the clamp
fuse.
Yellow)

8
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
CARTON CONTENTS
The following items should be supplied in the carton. if any parts are missing or
damaged, please contact the CLARKE dealer where you purchased the
bench grinder.
PART IDENTIFICATION
1 x Bench grinder assembly (c/w 2 grinding wheels attached)
2 x Eye shields and holders (1 with magnifying lens)
2 x Eye shield arms
2 x Eye shield brackets with bolts and washers
2 x Tool rest retaining nuts
2 x Spark deflectors with screws and washers
2 x Tool rests

9
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
BEFORE USE
MOUNTING THE GRINDER ONTO A WORKBENCH
NOTE: We highly recommend that you bolt this bench grinder securely to a
workbench to gain maximum stability.
1. Using the base of the bench
grinder as a template, mark the
bench through the holes in the
casting.
2. Bolt the bench grinder on the
bench with bolts, washers and nuts
(not supplied).
3. To reduce vibration, mount the
bench grinder on a vibration
absorbing mat.
INSTALLING THE TOOL RESTS
1. Fix the tool rests to the bench
grinder with the retaining nut as
shown.
• The tool rests are adjustable
and should be positioned 1.5
mm from the grinding wheels.
• Ensure that the tool rest is firmly
fixed and horizontal.
INSTALLING THE SPARK DEFLECTORS
Fit both the spark deflectors to the
wheel guards using the screws
provided.
• Adjust the spark deflector to
compensate for wear of the
wheel. Keep the distance
between the spark deflector
and wheel as small as possible
and never more than 2 mm.

10
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INSTALLING THE EYE SHIELDS
1. Attach the left eye shield arm to
the bench grinder using the
bracket, flat washer and bolt
supplied.
NOTE: Adjust the eye shields to an appropriate distance from the tool rests
avoiding interference during operation.
OPERATION
NOTE: Check that there is approx a 1.5 mm clearance between the tool rest
and the surface of the grinding wheel. Adjust as necessary.
NOTE: Check the gap between the spark deflectors and the surface of the
grinding wheel. These should also be a maximum of 2 mm. Adjust as
necessary.
NOTE: Check that the eyeshields have been secured in the correct position
and that the grinding wheel lock nuts are tight.
1. Stand to the side of the bench grinder and switch it on using the on/off
switch.
• Let the wheels reach full speed before use.
• The wheel rotates in the same direction as the arrow stamped in the
side of the wheel guard.
2. Hold the work piece firmly against the tool rest. Hold very small pieces with
pliers or other suitable clamps.
3. Press the workpiece smoothly and evenly against the grinding wheel.
4. Always keep the workpiece moving across the face of the wheel. Grinding
against the same part of the wheel will cause uneven wear of the wheel
face.
CAUTION: KEEP ALL BYSTANDERS A SAFE DISTANCE AND NOT IN DIRECT
LINE, FRONT OR BACK OF THE GRINDER.
CAUTION: ALWAYS WEAR SAFETY GLASSES.

11
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
• Grind only on the face of the grinding wheel and never the side of it.
NOTE: Prolonged grinding will cause tools/workpieces to become hot. Take
care when handling hot items.
5. Switch the bench grinder off using the on/off switch when you have
finished.
DRESSING THE GRINDING WHEEL
The grinding wheel may need dressing occasionally. Only dress the wheel with
a proper dressing tool, whilst wearing safety goggles or glasses. If in doubt seek
professional advice. Dressing tools are available from your CLARKE Dealer.
Grinding wheel dresser model no ET125;- part no 1700225
SHARPENING TIPS
SCISSORS
If possible, take the scissors apart to make the sharpening operation easier
and safer. Remove material only from the outside surface and work from the
heavy end of the blade toward the tip.
KNIVES
Remove metal from both faces of most knives, working from the large end of
the blade toward the tip.
REPLACING THE GRINDING WHEELS
The grinding wheel must be replaced
whenever the distance between the
external diameter of the wheel and
the edge of the grinding wheel cover
is greater than 6 mm.
1. Remove the screws shown and lift
off the cover.
2. Hold the other wheel by hand and
remove the nut and outer disc
from the damaged wheel.
WARNING: DO NOT USE DAMAGED GRINDING WHEELS.
WARNING: SWITCH THE GRINDER OFF AND DISCONNECT THE POWER
SUPPLY BEFORE CHANGING THE GRINDING WHEELS

12
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
NOTE: The left hand grinding wheel locking nut has a left handed thread.
3. Slide off the grinding wheel and replace with a new one. Be sure to fit the
paper discs between the new grinding wheel and the inner and outer
retaining discs.
• Only use grinding wheels recommended by the manufacturer which
have a marked speed rating equal to or greater than the speed
marked on the rating plate of the bench grinder.
• The disc should have maximum dimensions of 150 mm diameter, 25
mm thick with a bore size of 32 mm.
• Inspect the wheel for cracks, chips or any other visible damage.
Damaged grinding wheels must be discarded.
4. Replace the outer disc with the
boss entering the grinding wheel
and trapping the paper disc.
5. Replace the nut securely.
• Do not overtighten as this may
damage the grinding wheel.
6. Re-assemble the guards fully prior
to trial running the grinding wheel.
• Each time after mounting, the
wheel should be test run for a
reasonable time (approximately 1 minute) to demonstrate true
running.

13
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY

14
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PARTS DIAGRAM

15
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PART LIST
1 Screw M5 x 16 31 Housing (RH)
2 Bottom Foot 32 Motor Shaft
3 Cable Clamp 33 Stator
4 Earthing Point 34 Shaft Bearing 6205
5 Bolt 4mm 35 Housing (RH)
6 Washer 4mm 36 Domed Nut M6
7 Screw M5 x 10 37 Power Cable Gland
8 Bottom Plate 38 Washer 6mm
9 Cable Sheathing 39 Power Cable with Plug
10 Capacitor Clamp 40 Spark Deflector
11 Rubber Cover 41 Bracket
12 Power Switch 42 Grinding Wheel Inner Cover (RH)
13 Washer 43 Spark Deflector Mounting (RH)
14 Screw M4 x10 44 Coachbolt M6 x 12
15 Machine Frame 45 Bolt M5 x 8
16 Nut M5 46 Eye Shield Bracket
17 Locknut M10 47 Eye Shield Lens
18 Toolrest (LH) 48 Bolt
19 Spacer 49 Grinding Wheel
20 Screw M6 x12 50 Screw
21 Paper Disc 51 Paper Disc
22 Screw M5 x 55 52 Protective Cover (RH)
23 Outer Securing Disc 53 Outer Securing Disc
24 Protective Cover (LH) 54 Right Wheel Cover
25 Eye Shield Lens 55 Toolrest (RH)
26 Left Wheel Cover 56 Bolt M10 x 20
27 Eye Shield Arm (LH) 57 Screw M5 x 8
28 Grinding Wheel Inner Cover (LH) 58 Capacitor 25uf
29 Snap Ring 59 Snap Ring
30 Bolt 8 x 12 60 Washer 5mm