Clarke METALWORKER CHDBG900 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0320 - ISS 1
8”(200mm) BENCH GRINDER
MODEL NO: CHDBG900
PART NO: 6500540

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INTRODUCTION
Thank you for purchasing this CLARKE 8”(200mm) 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
By purchasing this product, the customer is taking on the obligation
to deal with its safe disposal in accordance with the Waste Electrical
and Waste Electronic Equipment regulations (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.

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SPECIFICATIONS
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.
Model number CHDBG900
Part number 6500540
Dimensions (D x W x H) 498 x 250 x 300 mm
Weight 26.3 kg
Rated voltage 230V~ 50 Hz
Rated input wattage 900W
No load speed 2850 RPM (+/- 5%)
IP rating IP40
Wheel shaft diameter 16 mm
Abrasive wheels supplied Coarse (36 Grit), Fine (60 Grit)
Wheel dimensions Diameter (200 mm)
Thickness (32 mm)
Bore (32 mm)
Duty Cycle classification S2/30 minutes
Sound power (measured) 97 dB LpA
Sound power (guaranteed) 98 dB LwA
Uncertainty factor K 1.67 dB

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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.
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.

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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) SERVICING
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. DO NOT grind any materials containing asbestos.
7. 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.
8. NEVER leave the grinder unattended when it is connected to an electrical
power supply. Switch off the grinder and unplug it before leaving.

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9. 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.
10. Gloves, manufactured to the current European safety standards should be
worn when operating grinding equipment.
11. 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
Wear dust mask

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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
at home.
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)

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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.
PARTS IDENTIFICATION
1 x Bench grinder assembly
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 rests with retaining nuts
2 x Spark deflectors with screws and washers
1 x Abrasive grinding wheel 36 grit (fitted)
1 x Abrasive grinding wheel 60 grit (fitted)

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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 bolts
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.

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INSTALLING THE EYE SHIELDS
1. Attach each eye shield arm to the
bench grinder using the clamp,
flat washer and bolt supplied.
2. Repeat with the right eye shielld.
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.
• Grind only on the face of the grinding wheel and never the side of it.
CAUTION: KEEP ALL BYSTANDERS A SAFE DISTANCE AND NOT IN DIRECT
LINE, FRONT OR BACK OF THE GRINDER.
CAUTION: ALWAYS WEAR SAFETY GLASSES.

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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
when the gap between the wheel
and the edge of the tool rest (in its
closest position to the wheel) is more
than approximately 6 mm.
This is to ensure the tool being
sharpened is correctly supported.
Adjust the tool rest with the retaining
nut to maintain the correct distance
as the wheel wears down.
WARNING: DO NOT USE DAMAGED GRINDING WHEELS.
WARNING: SWITCH THE GRINDER OFF AND DISCONNECT THE POWER
SUPPLY BEFORE CHANGING THE GRINDING WHEELS

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1. To remove the wheel, first remove the machine screws with nuts and
washers shown and lift off the cover.
2. Hold the other wheel by hand and
remove the nut and outer disc
from the damaged wheel.
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 200 mm diameter,
32 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.
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.
• After mounting, the wheel
should be test run for a
reasonable time
(approximately 1 minute) to demonstrate true running.
CONSUMABLES
Replacement grinding wheels are available from your CLARKE dealer as
follows:
REPLACEMENT FINE 200 mm GRINDING WHEEL 6500550
REPLACEMENT MEDIUM 200mm GRINDING WHEEL 6500552
REPLACEMENT COARSE 200mm GRINDING WHEEL 6500554

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DECLARATION OF CONFORMITY

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PARTS DIAGRAM

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PART LIST
1 Screw M5 x 16 31 Housing (LH)
2 Bottom Foot 32 Motor Shaft
3 Cable Clamp 33 Stator
4 Earthing Point 34 Shaft Bearing 6205
5 Washer 4mm 35 Housing (RH)
6 Washer 5mm 36 Domed Nut M6
7 Screw M5 x 10 37 Power Cable Gland
8 Mounting 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 Stud
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