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WALL CHASER
Model No: CON1500WC
Part No: 6462167
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC01/24
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INTRODUCTION
Thank you for purchasing this CLARKE Wall Chaser.
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.
Save these instructions including all safety warnings and instructions for future
reference.
SPECIFICATION
Cutting width 8-30mm
Cutting depth 5-29mm
Disc diameter 125mm
Disc thickness 2mm
Disc bore 22.23mm
Disc rated speed 12,200rpm/80m/s
Dust extraction outlet 35mm inner/52 mm outer
Operating voltage & frequency 230V - 50Hz
Insulation class II
Duty cycle classification S1 (continuous)
Rated wattage 1500 W
Weight 4.52 kg
Dimensions: Height x Width x Depth 165 x 390 x 165 mm
Power cable length 2 m
IP rating IPX0
Guaranteed sound power 108.1 dB(A)
Sound pressure level 97 dB(A)
Uncertainty factor 3 dB(A)
Vibration at handle
Uncertainty factor
3.239 m/s
1.5 m/s
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GENERAL POWER TOOL SAFETY WARNINGS
WARNING: READ ALL SAFETY WARNINGS AND ALL INSTRUCTIONS.
FAILURE TO FOLLOW THE WARNINGS AND INSTRUCTIONS MAY RESULT IN
ELECTRIC SHOCK, FIRE AND/OR SERIOUS INJURY.
1. Keep the work area tidy.
• Clutter in the work area can lead to accidents.
2. Take environmental influences into account.
• DO NOT expose power tools to rain.
• DO NOT use power tools in a damp or wet environment.
• Make sure that the work area is well lit.
• DO NOT use power tools where there is a risk of fire or explosion.
3. Protect yourself from electric shock.
4. Keep other persons away.
• DO NOT let persons, especially children, not involved in the work touch
the machine and keep them away from the work area.
5. Securely store unused power tools. Unused power tools should be stored in
a dry, elevated or enclosed location out of the reach of children.
6. DO NOT overload your power tool.
• They work better and more safely in the specified output range.
7. Use the correct power tool for the task.
• DO NOT use low-output power tools for heavy work.
• DO NOT use the power tool for purposes for which it is not intended.
8. Wear suitable clothing.
• DO NOT wear loose clothing or jewelry, which can become entangled
in moving parts.
• When working outdoors, anti-slip footwear is recommended.
• Tie back and restrain long hair.
9. Use protective equipment.
• Wear protective eye wear.
10. Wear a dusk mask when carrying out dust-creating work.
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POWER TOOL USE AND CARE
1. DO NOT force the power tool. Use the correct power tool for your
application. The correct power tool will do the job better and safer at the
rate for 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 supply before making any
adjustments, changing accessories. Such preventative safety measures
reduce the risk of starting the power tool accidentally.
4. Store idle power tools out of the reach of children and do not allow persons
unfamiliar with the power tool or these instructions to operate the power
tool. 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
tools operation. If damaged, have the power tool repaired before use.
Many accidents are caused by poorly maintained power tools.
6. Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
7. Use the power tool, accessories and tool bits etc in accordance with these
instructions and in the manner intended for the particular type of power
tool, taking into account the working conditions and the work to be
performed. Use of the power tool for operations different from those
intended could result in a hazardous situation.
8. Have your power tool serviced by a qualified repair person using only
identical component parts.
ADDITIONAL SAFETY RULES FOR WALL CHASERS
1. Always use the guard provided. The guard must be securely attached to
the wall chaser and positioned for maximum safety so the least amount of
cutting disc is exposed towards the operator. Position yourself and any
bystanders away from the plane of the rotating discs. The guard helps to
protect the operator from broken disc fragments and accidental contact
with the disc.
2. The rated speed of the cutting discs must be at least equal to the maximum
speed marked on the power tool. Cutting discs running faster than their
rated speed can break and fly apart.
3. The arbor size of the cutting discs and flanges must correctly fit the spindle
of the wall chaser. Discs with arbor holes that do not match the
components of the wall chaser will run out of balance, vibrate excessively
and may cause loss of control.
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4. Cutting discs must be used only for recommended applications. Side
forces applied to these discs may cause them to shatter.
5. DO NOT use damaged cutting discs. Before each use, inspect the discs for
chips and cracks. If the wall chaser or wheel is dropped, inspect for
damage or install an undamaged disc. After inspecting and installing the
disc, position yourself and bystanders away from the plane of the cutting
disc and run the wall chaser at maximum no load speed for one minute.
6. Hold the wall chaser only by the insulated gripping surfaces lest there is any
possibility cutting disc may contact hidden wiring or its own cable. ALWAYS
take great care by actively checking that there are no hidden electrical
cables or concealed pipes in line with the groove to be cut.
7. Position the power cable clear of the cutting discs. If you lose control of the
wall chaser the cable may be cut or snagged and your hand or arm may
be pulled against the cutting disc.
8. Never lay the wall chaser down until the cutting discs have come to a
complete stop. The cutting discs may grab the surface and pull the wall
chaser out of your control.
9. DO NOT run the wall chaser while carrying it at your side. Accidental
contact with the cutting disc could snag your clothing, pulling the
accessory into your body.
KICKBACK AND RELATED WARNINGS
Kickback is a sudden reaction to a pinched or snagged cutting disc. Pinching
or snagging causes rapid stalling of the rotating disc which in turn causes the
uncontrolled power tool to be forced in the opposite direction of the disc
rotation.
1. Maintain a firm grip on the power tool and position your body and arm to
allow you to resist kickback forces. Always use the auxiliary handle, (if
provided), for maximum control over kickback or any torque reaction
during start-up. The operator can control torque reactions or kickback
forces if proper precautions are taken. Never place your hand near the
cutting disc. The wall chaser may kickback over your hand.
2. DO NOT position your body in the area where the power tool will move if
kickback occurs. Kickback will propel the tool in the direction opposite to
the wheel’s movement at the point of snagging.
3. Take special care when working corners, sharp edges, etc. Avoid
bouncing and snagging the disc. Corners, sharp edges or bouncing have
a tendency to snag the dic and cause loss of control or kickback.
4. DO NOT “jam” the cut-off wheel or apply excessive pressure. DO NOT
attempt to make an excessive depth of cut. Over-stressing the wheel
increases the loading and susceptibility to twisting or binding of the wheel
in the cut and the possibility of kickback or wheel breakage.
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5. When wheel is binding or when interrupting a cut for any reason, switch off
the power tool and hold the power tool motionless until the wheel comes
to a complete stop. NEVER attempt to remove the cut-off wheel from the
cut while the wheel is in motion, otherwise kickback may occur. Investigate
and take corrective action to eliminate the cause of wheel binding.
6. DO NOT restart the cutting operation in the workpiece. Let the wheel reach
full speed and carefully re-enter the cut. The wheel may bind, walk up or
kickback if the power tool is restarted in the workpiece.
7. Use extra caution when making a “pocket cut” into existing walls or other
blind areas. The protruding wheel may cut gas or water pipes, electrical
wiring or objects that can cause kickback.
SAFETY SYMBOLS FOUND ON THE PRODUCT
The meanings of the markings and symbols on the product are shown below
Read this manual
before use and keep
in a safe place for
future reference
Gloves should be
worn when cutting.
Wear eye protection
when using this tool.
Wear dust mask.
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 Electronic Equipment (WEEE).
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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ELECTRICAL CONNECTIONS
Plug must be BS1363/A approved.
Always fit
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
a 13 Amp
the cable is firmly held by the clamp
fuse.
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS FULLY
BEFORE CONNECTING THE MACHINE TO THE MAINS SUPPLY.
This machine is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug,
for connection to a standard, domestic electrical supply. Should the plug
need changing, make sure that a plug of identical specification is used.
WARNING! THE WIRES IN THE POWER CABLE OF THIS PRODUCT
ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE
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 which
is marked N.
• Connect the brown
wire to the terminal
which is marked L.
We strongly recommend that this machine is connected to the mains supply
through a Residual Current Device (RCD)
If in doubt, consult a qualified electrician. DO NOT attempt any repairs yourself
This symbol indicates that this is a Class II product, and does not
require an earth connection.
CABLE EXTENSIONs
Always use an approved cable extension suitable for the power rating of this
machine. The conductor size should also be at least the same size as that on
the machine, or larger.
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BEFORE USE
INVENTORY
Unpack your wall chaser and make sure that the following items are present.
Should items be damaged or missing contact your CLARKE dealer
immediately. Note that the spacing discs should be fitted to the machine.
.
1. Wall Chaser
2. Pin Spanner
3. Detachable Handle
4. Breakout Chisel
5. Cutting Discs (125mm Diameter x 22.2mm Bore)
6. Pair carbon brushes
• Replacement cutting discs are available as part no; 6491036
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FITTING/REPLACING THE CUTTING DISCS
WARNING: DISCONNECT THE PLUG FROM THE POWER SUPPLY BEFORE
MAKING ANY ADJUSTMENTS OR CHANGING CUTTING DISCS.
WARNING: NEVER PRESS THE SPINDLE LOCK BUTTON WHEN THE MACHINE
IS RUNNING.
The spindle lock button prevents the
spindle from turning when you
unscrew and remove the outer
retaining disc (using the Pin Spanner
provided).
1. Release both the wingnuts
securing the cover plate and
swing it aside.
2. Use the pin spanner to release the
retaining disc and lift out the two
cutting discs and the width
adjustment spacers from the
machine.
3. Install the replacement cutting
discs together with as many
spacing discs as are required,
followed by the retaining disc.
• Always replace both cutting
discs at the same time as a
pair.
4. Tighten with the pin spanner while
locking the spindle with the
spindle lock button.
5. Re-position and secure the cover plate.
Replacement cutting discs are available as part number 6461036 from your
Clarke dealer.
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SETTING THE CUTTING WIDTH
The cutting width is determined by
the number of spacer discs you put in
between the discs.
• The cutting width is equal to:
The thickness of the 2 blades (2
x 2.5 mm) + the thickness of the
spacers.
• Make sure that the inner disc
boss is seated properly.
• All spacers must be used to
secure the cutting discs. Position the spacers on the outside of the
cutting discs to make the cutting width narrower.
FITTING THE HANDLE
Screw the handle into the hole shown
(left-hand thread).
FITTING A DUST EXTRACTION TUBE
Connect a suitable dust extraction
hose (not supplied) into the
extraction port (2) and twist to lock
into place.
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OPERATION
ADJUSTING THE CUTTING DEPTH
1. Loosen the depth adjustment
knobs.
2. Raise/lower the baseplate.
3. Use a ruler as shown to measure
the depth of the blade.
4. Tighten the adjustment knob.
5. The depth of cut should be set
3mm deeper than the required
slot depth.
SWITCHING ON / OFF
To switch on the machine, depress
the safety button before squeezing
the trigger.
To switch off, release the trigger.
USING THE WALL CHASER
Slots in structural walls are subject to
regulations which are to be observed under all circumstances. Consealed
cables and pipes should always run horizontally or vertically and their possible
locations must be identified before stating work.
1. Mark the surface to be worked.
2. Keep the wall chaser in an upright
position.
3. Move the wall chaser across the
surface using the guide wheel.
4. Always move the wall chaser in a
backwards (towards you)
direction.
5. Move at a constant speed. DO
NOT force the machine.
6. Remove the remaining material using the breakout chisel supplied.
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CARE AND MAINTENANCE
AFTER USE
1. Clean away any accumulated dust.
2. Check the condition of the cutting disc for signs of cracking, and discard
immediately if apparent.
3. Keep the cooling vents clear.
4. Clean the housing with a soft cloth. Any worn or damaged parts should be
replaced by qualified personnel.
5. The bearings in the machine are sealed for life and require no
maintenance.
6. Refer to qualified service personnel if internal maintenance is required.
CHANGING THE CARBON BRUSHES
1. Use a screwdriver to remove the
carbon brush covers from the
machine body (one on each
side).
2. Remove worn brushes and insert
new ones as a matching pair.
3. Replace the brush holder covers.
STORAGE
1. Store the machine in a clean, dry
place, out of reach of children when not in use.
2. Always store in the case supplied.
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.
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DECLARATIONS OF CONFORMITY
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COMPONENT PARTS LIST
ID DESCRIPTION ID DESCRIPTION ID DESCRIPTION
1 Scale plate 31 Washer 61 Brush holder
2 Active cover 32 Dust seal washer 62 Carbon brush
3 Flat washer 33 Dust tube 63 Brand label
4 Adjusting knob 34 Dust cover 64 Air duct
5 Cover 35 Screw M4 x 16 65 Screw
6 Brand label 36 Front cover 66 Stator
7 Cover knob 37 Sealing washer 67 Tension spring
8 Allen screw M6 x 30 38 Bearing 6201-2RS 68 Housing
9 Spring washer 39 Bearing press plate 69 Brand label
10 Flat washer 40 Screw M4 x 12 70 S/t Screw
11 Upper cover 41 Semi circular 71 Speed control
12 Upper bush 42 Primary gear 72 Screw M5 x 65
13 Diamond saw blade 43 Soft washer 73 Spring washer
14 Positioning plate 44 Bearing HK081410 74 Washer
15 Lower bush 45 Upper guard 75 Right handle
16 Dust retaining ring 46 Self locking pin 76 Capacitor
17 Shaft 47 Spring 77 Switch
18 Screw M4 x 10 48 Washer 78 Switch button
19 Spring washer 49 Screw 79 Cable sleeve
20 Dust baffle 50 Allen screw 80 Cable
21 Active guard 51 Secondary wheel 81 Compression spring
22 Lower fixed guard 52 Bearing 6000-2RS 82 Release button
23 Allen screw M6x25 53 Press plate 83 Left handle
24 Flexible gasket 54 Washer 84 Cable clamp
25 Guidewheel pillar 55 Screw M5 x 12 85 Side handle
26 Flat washer 56 Rotor 86 Wrench
27 Guidewheel tube 57 Bearing 627-2RS 87 Breakout chisel
28 Guidewheel 58 Bearing sleeve 88 Handle sleeve
29 Screw M8x30 59 Ring
30 Dust casing 60 Brush cover
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