4 Angle Grinder

Model CAG122
Part Number 6470127

Operating & Maintenance

Instructions

0807

Specifications
Model No ................................................................. CAG 122
Part No ..................................................................... 6470127
Supply Voltage ........................................................ 230 V AC, 50 Hz, 1 Phase
Motor input wattage .............................................. 900Watts
Fuse Rating ............................................................... 13A
Insulation Class ........................................................ II (Double Insulated)
No Load Speed ....................................................... 10,000 RPM
Sound Pressure level ............................................... 89.7 dB(A)
Vibration Level (see P 12) ....................................... 13.2m/s2
Maximum Cutting Wheel Diameter ..................... 115mm
Cutting Wheel Bore ................................................. 22mm
Drive Spindle Thread ............................................... M14
Tool Weight .............................................................. 2.3kg

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

Do not dispose of this product with general household waste. It must be disposed of according
to all laws governing the disposal electrical and electronic waste, at a proper disposal facility.

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Contents
Specifications ............................................................................................. 2
Guarantee .................................................................................................. 3
Features and Use ....................................................................................... 3
For your Own Safety ................................................................................... 4
General Safety Precautions : For Power Tools ........................................ 4
Safety Precautions : For Angle Grinders .................................................. 5
Electrical Connections .............................................................................. 6
Overview of your Angle Grinder .............................................................. 7
Mounting the Grinding Wheel / Cutting Disk .......................................... 8
Maintenance .............................................................................................. 9
Troubleshooting ......................................................................................... 10
Parts and Service Contacts ..................................................................... 10
Spare Parts Diagram ................................................................................. 11
Spare Parts List ........................................................................................... 11
Recommended Grinding Wheels / Cutting Disks .................................. 11
Vibration Emissions .................................................................................... 12
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 only. The grinder
features a moveable guard, a spindle lock and a safety ON/OFF switch.
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For Your Own Safety

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.
General Safety Precautions : For Power Tools
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
before the tool is used.

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.

If in doubt Do Not use the tool. Consult your Do Not carry the tool by its electric cable, or
yank the cable to disconnect it from the
local dealer.
power supply.
Always ensure that adequate lighting is
Always ensure the switch is OFF before
available. A minimum intensity of 300 lux
should be provided. Ensure that lighting is plugging in to mains. This will ensure the
placed so that you will not be working in your equipment does not start accidentally.
own shadow.
Always follow the maintenance instructions.
Always
wear
safety
goggles Keep tools clean and maintained for the
manufactured to the latest European Safety best and safest performance.
Standards, everyday eyeglasses do not have
Never force the tool. It will do a better
impact resistant lenses, they are NOT safety
and safer job at the rate for which it was
glasses.
designed.
Always use a face or dust mask if
Never operate equipment while under
operation is particularly dusty.
the influence of Drugs, Alcohol or any
Always disconnect the tool from the Medication.
power supply before servicing and when
Do Not overreach. Keep your proper
changing accessories.
footing/balance at all times. For best footing
Always use in a suitable environment. wear rubber soled footwear. Keep floor clear
Dont use power tools in damp or wet of oil, scrap wood, etc.
locations or expose them to rain. Keep your
Only Use recommended accessories.
work area well illuminated. Do Not use in
The
use
of improper accessories could be
explosive atmosphere. (i.e near flammable liquids etc.).
hazardous
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Additional Safety Precautions : For Angle Grinders

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.
worn

A Dust Mask manufactured to the current European Safety Standard should be

when operating grinding equipment.
WARNING ! Ensure all accessories used are rated at the spindle speed, or higher.
WARNING ! Never press the spindle lock while the disc is rotating.

Never use excessive force. It should only

Always wear a good pair of industrial
gloves to avoid potential injury from sparks be necessary to use a little more than the
weight of the tool. If the rotational speed
and debris.
drops abnormally, reduce pressure
Always keep the mains cable well away immediately. Forcing the tool and excessive
from the tool. Ensure an adequate electrical pressure can cause dangerous disc
supply is close at hand so that the operation is breakage and/or
damage to the tool.
not restricted by the length of the cable.
Never allow the ventilation slots in the
Always switch the tool OFF immediately tool to become blocked.
when the task is completed.
Never use the tool with the guard
Always ensure the grinding wheel or removed. If the guard becomes damaged,
cutting disc is fully tightened before use.
it must be replaced
Always ensure the wheel / disc is not
Never use the tool in a confined space
touching the work when switching ON.
which may limit body movement.
Always allow the Grinder to run briefly
Use only wheels/discs designed for their
before using. Check for vibration which could specific function. (see page 11)
indicate poor balance or installation of the
Beware of flying sparks. Hold the grinder
wheel/disc.
at an angle of 15 - 30O to the workpiece
Always hold the tool firmly in BOTH hands surface (as shown in figure (2)).
(as shown in figure (1)).

(1)

(2)

15 - 30O

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Electrical Connections
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 N or coloured Black

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

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Figure (1) Overview

6

2
1

Safety ON/OFF Switch

Handle

Spindle Lock Button

Abrasive Disk

Moveable Blade Guard

Body

Before Using the Grinder

Fit the Handle : Screw the handle (4) into the appropriate position in the grinder head
as required.

Figure.1a Adjusting the Guard

Adjust the Guard : The guard (3) needs

to be adjusted to give maximum
protection from sparks and debris
produced when grinding. This must be
done before mounting the wheel/disk.
Slacken the four screws, arrowed in Fig
1a by half a turn only, sufficiently for the
guard to be rotated to its desired
position. When satisfied, tighten all four
screws securely.
Mount the Grinding Wheel / Cutting Disc
: See page 8 for details
Connecting 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.
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(i)

Mounting the Grinding Wheel / Cutting Disc

Unscrew and remove the outer flange :

Lock the spindle by pressing the spindle
lock button and use the tool supplied to
turn the flange and break the seal. It
may then be screwed off by hand.

Mount the Grinding Wheel, as shown in

Figure 2. The grinding wheel supplied is
a Depressed Centre type. Mount with
the depressed centre towards the motor.

Screw on the Outer Flange with the raised

boss facing inwards, ensuring the wheel
or disk 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 overtighten the outer
flange.

Figure (2) Mounting Discs

IMPORTANT ! Fig (2) shows the set up for a grinding wheel.

WHEN ATTACHING A CUTTING DISC YOU MUST REVERSE THE OUTER FLANGE

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 push the switch fully forwards. To Stop the Motor press down on the
rear of the switch.
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.

Before Each Use

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

After every 50 hours of use the motors carbon brushes need to be checked and renewed
if necessary. You will need a cross head screwdriver and a small flat head screwdriver. The
brushes are changed as follows :
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)
3 If the brush is worn (less than 6mm remains, see (C))
then replace the brush assembly by clipping a new
one into place (D). Replace the casing and secure with
the casing screw taking care not to damage the lead.
B

Casing Screw

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Troubleshooting
Problem

Possible Cause

Tool will not operate

1. No supply

1. Check supply and rectify

where necessary.

Repair

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

broken

2. Consult your Clarke dealer

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

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:

020 89887400

Parts and Service Fax: 020 85583622

or email as follows:

Parts: [email protected]
Service: [email protected]
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Spare Parts Diagram (Figure 3)

Spare Parts List

No.

Part No.

Description

Motor Brush

HT12201

Handle

HT12202

Wheel/Disk Guard

HT12203

Inner Flange

HT12204

Outer Flange

HT12205

Grinding Wheel / Cutting Disc

( See Clarke Accessories below )

Flange Tool

HT12207

Casing

HT12208

Recommended Grinding Wheels / Cutting Discs

Clarke Accessories
Description

Part No.

Dia

Thickness

Metal Grinding (DPC)

6470705

115mm

6mm

Metal Cutting (DPC)

6470775

115mm

3mm

Masonry Cutting (DPC) 6470735

115mm

3mm

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VIBRATION EMISSIONS
HAND-ARM VIBRATION
Employers are advised to refer to the HSE publication Guide for Employers.
All hand held power tools vibrate to some extent, and this vibration is transmitted to the
operator via the handle, or hand used to steady the tool. Vibration from about 2 to 1500
herz is potentially damaging and is most hazardous in the range from about 5 to 20 herz.
Operators who are regularly exposed to vibration may suffer from Hand Arm Vibration
Syndrome (HAVS), which includes dead hand, dead finger, and white finger. These
are painful conditions and are widespread in industries where vibrating tools are used.
The health risk depends upon the vibration level and the length of time of exposure to
itin effect, a daily vibration dose.
Tools are tested using specialised equipment, to approximate the vibration level generated
under normal, acceptable operating conditions for the tool in question. For example, a
grinder used at 45 on mild steel plate, or a sander on soft wood in a horizontal plane
etc.
These tests produce a value a, expressed in metres per second per second, which
represents the average vibration level of all tests taken, in three axes where necessary.

MODEL No:

CAG122

DESCRIPTION:

ANGLE GRINDER

Declared vibration emission value in accordance

with EN12096
Measured vibration emission value - a: 13.2 m/s2
Value determined according to EN28622-1

a values in excess of 2.5 m/s2 are considered hazardous when used for prolonged periods.
A tool with a vibration value of 2.8 m/s2 may be used for up to 8 hours (cumulative) per day,
whereas a tool with a value of 11.2 m/s2 may be used for hour per day only.

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The graph below shows the vibration value against the maximum time the respective tool
may be used, per day.
It should be noted that if a tool is
used under abnormal, or unusual
conditions, then the vibration
level could possibly increase
significantly. Users must always
take this into account and make
their own risk assessment, using
the graph above as a reference.
Some tools with a high vibration
value, such as impact wrenches,
are generally used for a few
seconds at a time, therefore the
cumulative time may only be in the order of a few minutes per day. Nevertheless, the
cumulative effect, particularly when added to that of other hand held power tools that
may be used, must always be taken into account when the total daily dose rate is
determined.

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DECLARATION OF CONFORMITY

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