Clarke CAG120 Installation and operation manual

0402
©
Operating & Maintenance
Instructions
4½ ” (115mm)
ANGLE GRINDER
Part Number 6470120
Model CAG120
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]
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If you have any problems using or setting up your Grinder
call the Clarke Helpline on :
020 8988 7400
Press 1 for Parts : 2 for Technical Assistance
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Spare Parts Diagram (fig 3)
No Description Part No.
1 OuterFlange HT120035
2 Grinding Disc SeeBelow
3 InnerFlange HT120033
4 DiscGuard HT120032
5 Brush Cap HT120045
6 Handle HT120018
7 PegSpanner HT120058
- Carbon Brush HT120044
Spare Parts List
Recommended Grinding Wheels / Cutting Discs
Clarke Accessories
No. Description Part No. Dia Thickness
1 Metal Grinding (DPC) 6470705 115mm 6mm
2 Metal Cutting (DPC) 6470775 115mm 3mm
3 Masonry Cutting (DPC) 6470735 115mm 3mm
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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
Specifications .................................................................................................. 9
Spare Parts Diagram ....................................................................................... 10
Spare Parts List ................................................................................................. 10
Recommended Grinding Wheels / Cutting Discs ...................................... 10
Thank you for purchasing this Clarke Angle Grinder. Before putting to use, please
readtheseinstructionscarefully.Thisisforyourownsafetyandthatofothersaround
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
ThisAnglegrinder is a hand heldpowertool that uses abrasive disks togrindmetals
or masonry. It is intended for D.I.Y use only. 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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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. 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.
Ifextension cableis 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 120
Part No ..................................................................... 6470120
Supply Voltage ........................................................ 230 V AC, 50 Hz, 1 Phase
Fuse Rating............................................................... 13A
InsulationClass ........................................................ E
No Load Speed ....................................................... 11,000RPM
Maximum Cutting Wheel Diameter ..................... 115mm
Cutting Wheel Bore ................................................ 22mm
Drive Spindle Thread ............................................... M14
ToolWeight............................................................... 2.5kg
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. Always consult the machines data plate

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Always keep workareaclean andclear.
Clutteredareas and benchesinvite
accidents.
Always wear proper apparel. Loose
clothing or jewellery may get caught in
movingparts. Wearprotective hair
covering to contain long hair.
Always handleequipment with care.Do
Not carry the tool by its’ electric cable,
or yank the cable to disconnect it from
the power supply.
Always ensurethe switch is OFF before
plugging in to mains. This will ensure the
equipmentdoes not startaccidentally.
Always followthemaintenanceinstructions.
Keeptoolscleanandmaintainedforthebest
andsafestperformance.
Never force the tool. It will do a better
andsafer job at therate for which it was
designed.
Never operateequipment 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.
OnlyUse 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 checkfor damagebefore using
the tool. Any damaged part should be
checked to ensure that it will operate
properly and perform its intended
function.Check for alignmentof moving
parts,breakage of parts, mountingsand
anyother condition that mayaffectthe
tools’operation. Any damageshould 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
manufacturedto the latestEuropean
SafetyStandards, everydayeyeglasses
donot have impactresistant lenses, they
are NOT safety glasses.
Always use a face or dust mask if
operation is particularly dusty.
Always disconnect the tool from the
powersupply before servicingand when
changingaccessories.
Always useinasuitableenvironment.Don’t
usepowertoolsindamp orwetlocationsor
expose them to rain. Keep your work area
well illuminated. Do Not use in explosive
atmosphere.(i.enearflamableliquids etc.).
General Safety Precautions : For Power Tools
3
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8
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
renewedif nessessary
Before Each Use
After Every 50 Hours of use
1Unscrew theBrush end Caps, shown at 6, Fig 1.
2Withdraw the brushassembly
2If the brush is worn (less than 6mm left, see (C)) then
replace the brush assembly by clipping a new one
intoplace. Replace the Capsand secure
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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)
4
Always wear a good pair of industrial
gloves to avoid potential injury from
sparks and debris .
Always keepthe mains cablewell away
fromthetool.Ensureanadequateelectrical
supplyiscloseathandsothattheoperation
isnot restrictedby thelength ofthe cable.
Always switchthe tool OFF immediately
whenthe 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 holdthe toolfirmly inBOTH hands
(as shown in figure (1)).
Never use excessive force.It should only
benecessarytousea littlemorethan the
weight of the tool. If the rotational speed
dropsabnormally,reducepressure
immediately.Forcingthetoolandexcessive
pressurecancausedangerousdisc
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 guardbecomes
damaged, it should be replaced
Never use the tool in a confined space
which may limit body movement.
Use only wheels/discsdesigned for their
specificfunction.(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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7
Unscrew and remove the outer flange :
If it is tight, lock the spindle by pressing
the SpindleLockbuttonand use thetool
supplied to turn the flange to break the
seal.It maythen bescrewed offby hand.
Mount the Grinding Wheel : As shown in
the diagram. The Grinding wheel
supplied is a Depressed Centre’ type.
Mountwiththe depressedcentre towards
themotor.
Screw on the Outer Flange : With the
centre boss facing inwards ensuring the
wheel sits snugly over the raised boss on
theinner flange.Tighten the flangeusing
thetool provided, locking the spindleby
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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5
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. Neverusethe plug without the fusecover fitted.
3. Shouldyou wishto replacea detachablefuse carrier,ensure thatthe correctreplacement
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
replacementmust be ASTA approvedto BS1362.
IMPORTANT: If in any doubt, do not attempt any electrical repair yourself. Consult a
qualified technician
Double Insulated Electrical Appliance
Thisappliance isof Double Insulation Construction. Becauseof this,thereis noEarth conductor
in the mains supply cable.
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 : Connectto the powersupply using aResidual 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.
6
3 4
5
2
1
1 SafetyON/OFF Switch
2 SpindleLock Button
3 AdjustableGuard
4 Handle
5 Abrasive Disk
6 Carbon Brush Caps
Figure (1) Overview
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