angle grinder original instructions assembly

angle grinder original instructions assembly
Comply with all safety precautions and
instructions when using your BluCave products.
Need some inspiration or support? The BluCave
website opens-up a whole new world of DIY.
You can ask for help, gain real time product
information, share ideas and receive regular
updates on special BluCave offers.
The Angle Grinder can be used for cutting and
grinding metal, concrete, stone, timber and many
other materials.
You’re one of the growing community who have
embraced the BluCave work zone!
The BluCave Angle Grinder is one of the many
convenient AC ToolBods (power tool bodies) that
clicks into your BluCave AC Controller.
Assembly....................................................................... 1
ToolBod and Controller................................................. 1
Guard............................................................................. 2
Carrying......................................................................... 4
Note: BluCave offer both AC (powered) and DC (cordless)
operated Controllers and ToolBods. AC ToolBods will only
operate with an AC Controller and DC ToolBods will only
operate with a DC Controller. For simple identification
look for the appropriate colour marking with green
representing AC and orange representing DC.
Mounting Wheels and Discs........................................ 4
Fitting Wire Brushes..................................................... 6
Auxiliary Handle............................................................ 7
Operation...................................................................... 7
Switching On/Off.......................................................... 7
Speed............................................................................ 8
Storage.......................................................................... 9
Align the fixed hook (Grey)
of the Controller into the
corresponding recess on the
underside of the ToolBod.
Once located and engaged,
close the two faces of the
Controller and ToolBod
together until they click into
Cleaning/Servicing....................................................... 10
General Safety Warnings.............................................. 14
Grinder Safety Warnings...............................................19
Kickback Warnings....................................................... 22
Grinding and Abrasive Cut Off Warnings..................... 24
Wire Brushing Warnings............................................... 27
CONTROLLER (sold seperately)
1. Live Tool Indicator
2. Cord guard
3. Lock Button
4. Trigger
5. Variable Speed Dial
6. Controller Unlock Button
7. Auxiliary Handle
8. Clamp Nut
9. Inner Flange
10. Guard
11. Spindle lock
12. Wrench
Caution: All assembling, mounting, disassembling and
removing should be done with the Angle Grinder turned
off. Remove the power cord from the power supply.
The auxiliary handle must be fitted whenever the Angle
Grinder is in operation. It can be positioned on either
side. Simply screw the auxiliary handle clockwise to lock
it into place and screw anti-clockwise to remove it.
Caution: Check that the voltage of your power supply
matches the specified voltage on the ToolBod and on
the Controller. If the voltages of either the Toolbod or
Controller do not match the power supply voltage do not
use the unmatched item/s.
Caution: Always ensure the cord guard is extended and
the tool is not used with it in the `storage’ position. See
AC Controller instructions for details.
AC Angle Grinder TAG-115-1 EU EN REV 08.indd 1
Caution: Always ensure the workpiece is properly
supported and secure before grinding or cutting.
When in doubt always ask for advice.
Always wear protective clothing.
Always work in an uncluttered environment.
Allow the disc to reach full speed before making
contact with the work surface. Control the
pressure and surface contact between the
grinding disc and your work piece to ensure
optimum disc speed. Grinding flat surfaces are
usually done on an acute angle. Too great an
angle causes concentration of pressure on a small
area which may gouge or burn the surface of your
work piece.
ACCESSORIES: A set of accessories is available as a
starter kit for each BluCave ToolBod.
Cabinets provide storage options for the complete
BluCave range and even your existing tools. They
can be used as portable cases or mounted on the
BluCave Rail as stylish cabinets.
BOOSTERS: You can even ‘boost’ your BluCave to
include power, light and audio.
Visit to view the complete work zone.
place. (It’s as easy as Hook, Swing and Click) See Fig. 1.
Ensure the tool is switched off before trying to remove
the Controller. Press the unlock symbol located on the
Controller and then turn the ToolBod away from the
Important: Never use the Angle Grinder without the
guard in cutting or grinding applications or unless
specific accessories instruct its removal.
The Angle Grinder has a convenient rotating guard.
Caution: Always disconnect the power before fitting,
removing or rotating the guard. The guard must always
be rotated on the tool to suit the application where the
closed side protects the user.
Place guard over spindle as shown in Fig. 2.
Place guard retaining plate
over spindle ensuring the four 2
screw holes are indented (not
Align with the four screw
holes on the grinder body and
fasten screws to a minimum
of 1.2Nm and maximum of
Ensure the Controller and ToolBod are fitted correctly
and the disc/wheel is securely in place before
Plug the power cord into the power supply (and switch it
on if it’s switchable).
The blue power indicator will illuminate on the Controller
once connected to the power supply.
Squeeze the trigger to start the Angle Grinder. Keep the
trigger depressed to keep the Angle Grinder operating.
Release the trigger to stop the Angle Grinder.
To provide stable speed the power can be locked-on
by pressing the lock button on the Controller when the
trigger is completely depressed.
Remove any discs or accessories - (see Mounting
Grinding Wheels or Cutting Discs.)
Remove the four screws.
Remove guard retaining plate and the guard will detach.
Remove disc, loosen screws, grasp the guard firmly with
one hand whilst holding the body of the Angle Grinder.
Rotate the guard to the desired position. Tighten
screws as per procedure above and replace/fit disc.
Important: During operation with a grinding or cutting
disc note the position of the guard in relation to the
work piece, your hands and any part of your person.
Always rotate the guard to ensure it protects you from
any sparks or flying debris.
Alternating Current
Rated speed
Revolutions or reciprocations per minute
Decibels (A Weighted)
Average vibration
Newton metres of torque
Double Insulated Construction
When lifting or carrying your Angle Grinder always pick
it up by the main body grip area or the loop grip on the
Caution: Never carry the tool with your hand on the
Note: Ensure the grinding wheel, cutting disc or
accessory item is correctly mounted and tightened
before use and run the tool with no load for 30
seconds in a safe position. Stop immediately if there is
considerable vibration or if other defects are detected.
If this occurs check the machine to determine the
Note: The Angle Grinder is designed to be fitted with
depressed center grinding wheels or, cutting off wheels
when an enclosed type guard is fitted (Not Included).
Please contact the Distributor shown on page 12 to
purchase enclosed guard part number CGTAG-115 if you
wish to use a cut off wheel.
The Angle Grinder comes with two 40mm flanges that
are used to clamp a wide variety of accessories. The
fitting of the flanges is extremely important.
Note: The direction of the clamp nut will change for
cutting or grinding.
Caution: Always inspect the grinding wheel, cutting disc
or accessory before use. Do not use chipped, cracked
or otherwise defective parts.
Position the inner flange (which has no thread) onto the
spindle. Locate the two flats, with the two flat sections
on the spindle. See Fig.3.
Position the disc/wheel onto the spindle against the
inner flange with the disc/wheel label facing toward
the grinder. The hole in the disc/wheel should fit neatly
over the raised circular section of the inner flange.
Position the clamp nut
(which has an internal
thread) onto the spindle:
a) For Grinding Wheels:
Ensure the clamp nut raised
section faces towards the
disc/wheel. (Shown Fig. 3.)
b) For Cutting Discs: Ensure the clamp nut raised
section faces away from the disc/wheel.
Screw the clamp nut onto the spindle in a clockwise
direction. Depress the spindle lock button on the head
of the Angle Grinder and rotate the disc/wheel and
spindle so that the spindle locks. With the supplied
wrench, position the two pins of the wrench into any
two of the holes in the outer flange. While continuing
to depress the spindle lock button, rotate the wrench in
a clockwise direction until the flange is firmly clamping
the disc/wheel. Do not over tighten. Release the
spindle lock button. To remove disc/wheel reverse the
procedure above. See Fig.4.
Most wire brushes fit directly
onto the spindle.
(Flanges are not required.) Fit
the wire brush according to the
instructions supplied with it.
9 10 11 12
ToolBods come with their own unique storage dock for
compact and protective housing inside the BluCave
Carry Cabinets See Fig. 5
Squeeze the trigger fully to release the lock-on feature
then release the trigger to stop the Angle Grinder.
As the Angle Grinder ToolBod is designed for single speed
only, the variable speed function on your Controller will
not operate.
After working with materials that produce fine particles
such as dust from bricks or metal filings always allow
the Angle Grinder to run with no load in a dust free
environment. This will help to clear particles from the
internal parts. It is recommended to flow compressed
air through the air vents to further assist this process.
Regularly clean the housing with a soft cloth to
ensure the Angle Grinder does not become slippery or
excessively dirty.
Deutschland | Kundenservice
Montag bis Freitag von 9 bis 17 Uhr
01805 937832*
Keep the Angle Grinder clean and dust free.
Always ensure the ventilation slots plus the AC ToolBod
and AC Controller connector are free of any dirt or dust
This Batavia product comes with a 2 year warranty.
Dear Client, all Batavia products have undergone a strict
quality process. If for any reason this product is not
working or damaged , please contact our Client Service
Centre. Please retain your original receipt of purchase.
The Batavia warranty covers all defects in workmanship
or materials for a two year period from the date of
purchase. The Batavia warranty does not cover any
malfunction, or defect resulting from misuse, neglect,
alteration, or repair.
Have your power tool serviced by a qualified repair person
using only identical replacement parts. This will ensure
that the safety of the power tool is maintained.
Other European countries | Customer Services
Monday till Friday from 8 am until 4 pm
00800 66477400
A lubricant has been applied to the gear box that will
last the life of the tool. You are not required to lubricate
the tool during its normal working life.
Website: | Email:
Batavia GmbH
Blankenstein 180
7943 PE Meppel - Netherlands
Office phone: +31 (0) 522 820200
*Nur €0,14 /Minute aus dem dt. Festnetz,
max. €0,42/Minute aus den Mobilfunknetzen.
22/06/2004 1:50:14 AM
Angle Grinder
Rated Power Input
Grinding Wheel Diameter
Rated Speed
Spindle Thread
MODEL: TAG-115-1
115mm x 6mm
11000 min-1
230V 50Hz
BluCave tools are for private use only and are not
suitable for commercial/professional/continuous use.
Measured values determined according to EN 60745
Typically the A-weighted noise levels of the product are:
90.9 dB(A)
Sound Pressure Level LpA
101.9 dB(A)
Sound Power Level LWA
3 DB(A)
Uncertainty KpA
Uncertainty KWA
3 DB(A)
Wear Hearing Protection!
The following symbols are important for reading and
understanding the operating instructions. Please take
note of the symbols and their meaning. The correct
interpretation of the symbols will help you to use the
machine in a better and safer manner.
WARNING - To reduce the risk of injury during
operation, always read the instructions.
Always wear a dust mask. When working with wood
and other materials, harmful dust may be generated.
Work with asbestos containing materials is not
Always wear safety glasses. When working with
electric power tools, sparks, splinters, chips and dust
particles may be generated and these can cause loss
of sight.
The use of cut off wheels, wire brushes or other accessories may have different vibration emission values.
The sound intensity level for the operator may exceed
85dB(A) and sound protection measures are necessary.
The values given are valid for nominal voltages of 230V.
For lower voltage and models for specific countries these
values can vary.
The declared vibration total value has been measured in
accordance with a standard test method and may be used
for comparing one tool with another.
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.
The vibration emission during actual use of the power
tool can differ from the declared total value depending on
the ways in which the tool is used. Safety measures to
protect the operator should be identified that are based
on an estimation of exposure in the actual conditions of
use (taking account of all parts of the operating cycle such
as the times when the tool is switched off and when it is
running idle in addition to the trigger time).
a.Keep work area clean and well lit. Cluttered or dark
areas invite accidents.
b.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.
c.Keep children and bystanders away while operating a
TAG-115-1-EU-EN-REV 08
AC Angle Grinder TAG-115-1 EU EN REV 08.indd 2
© Demain International P/L 10/2011
a.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 serious personal
b.Use personal protective equipment. Always wear eye
protection. Protective equipment such as dust mask,
non-skid safety shoes, hard hat, or hearing protection
used for appropriate conditions will reduce personal
c.Prevent unintentional starting. Ensure the switch is
in the off-position before connecting to power source
and/or battery pack, picking up or carrying the tool.
Carrying power tools with your finger on the switch or
energising power tools that have the switch on invites
d.Remove any adjusting key or wrench before turning
the power tool on. A wrench or a key left attached to a
rotating part of the power tool may result in personal
WARNING Read all safety warnings designated by the
symbol and all instructions.
a.This power tool is intended to function as a grinder,
wire brush or cut-off tool. Read all safety warnings,
instructions, illustrations and specifications provided
with this power tool. Failure to follow all instructions
listed below may result in electric shock, fire and/or
serious injury.
b.Operations such as sanding, or polishing are not
recommended to be performed with this power tool.
Operations for which the power tool was not designed
may create a hazard and cause personal injury.
c.Do not use accessories which are not specifically
designed and recommended by the tool manufacturer.
Just because the accessory can be attached to your
power tool, it does not assure safe operation.
d.The rated speed of the accessory must be at least
equal to the maximum speed marked on the power tool.
Accessories running faster than their rated speed can
come to a complete stop. The spinning accessory may
grab the surface and pull the power tool out of your
Do not run the power tool while carrying it
at your side. Accidental contact with the spinning
accessory could snag your clothing, pulling the
accessory into your body.
n.Regularly clean the power tool’s air vents. The motor’s
fan will draw the dust inside the housing and excessive
accumulation of powdered metal may cause electrical
o.Do not operate the power tool near flammable
materials. Sparks could ignite these materials.
p.Do not use accessories that require liquid coolants.
Using water or other liquid coolants may result in
electrocution or shock.
Kickback is a sudden reaction to a pinched or snagged
rotating wheel, backing pad, brush or any other
accessory. Pinching or snagging causes rapid stalling
of the rotating accessory which in turn causes the
uncontrolled power tool to be forced in the direction
opposite of the accessory’s rotation at the point of the
of cut-off wheel. Abrasive cut-off wheels are intended
for peripheral grinding, side forces applied to these
wheels may cause them to shatter.
d.Always use undamaged wheel flanges that are of
correct size and shape for your selected wheel. Proper
wheel flanges support the wheel thus reducing the
possibility of wheel breakage. Flanges for cut-off
wheels may be different from grinding wheel flanges.
e.Do not use worn down wheels from larger power tools.
Wheel intended for larger power tool is not suitable for
the higher speed of a smaller tool and may burst.
e.Do not overreach. Keep proper footing and balance at
all times. This enables better control of the power tool
in unexpected situations.
f. 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.
g.If devices are provided for the connection of dust
extraction and collection facilities, ensure these are
connected and properly used. Use of dust collection
can reduce dust-related hazards.
break and fly apart.
e.The outside diameter and the thickness of your
accessory must be within the capacity rating of your
power tool. Incorrectly sized accessories cannot be
adequately guarded or controlled.
f. The arbour size of wheels, flanges, backing pads or
any other accessory must properly fit the spindle of the
power tool. Accessories with arbour holes that do not
match the mounting hardware of the power tool will
run out of balance, vibrate excessively and may cause
loss of control.
g.Do not use a damaged accessory. Before each use
inspect the accessory such as abrasive wheels for
chips and cracks, backing pad for cracks, tear or
excess wear, wire brush for loose or cracked wires.
If power tool or accessory is dropped, inspect for
damage or install an undamaged accessory. After
inspecting and installing an accessory, position
yourself and bystanders away from the plane of the
rotating accessory and run the power tool at maximum
no-load speed for one minute. Damaged accessories
will normally break apart during this test time.
h.Wear personal protective equipment. Depending on
application, use face shield, safety goggles or safety
For example, if an abrasive wheel is snagged or
pinched by the workpiece, the edge of the wheel that
is entering into the pinch point can dig into the surface
of the material causing the wheel to climb out or kick
out. The wheel may either jump toward or away from
the operator, depending on direction of the wheel’s
movement at the point of pinching. Abrasive wheels
may also break under these conditions.
glasses. As appropriate, wear dust mask, hearing
protectors, gloves and workshop apron capable of
stopping small abrasive or workpiece fragments. The
eye protection must be capable of stopping flying
debris generated by various operations . The dust mask
or respirator must be capable of filtrating particles
generated by your operation. Prolonged exposure to
high intensity noise may cause hearing loss.
i. Keep bystanders a safe distance away from work area.
Anyone entering the work area must wear personal
protective equipment. Fragments of workpiece or of
a broken accessory may fly away and cause injury
beyond immediate area of operation.
j. Hold the power tool by insulated gripping surfaces
only, when performing an operation where the cutting
accessory may contact hidden wiring or its own cord.
Cutting accessory contacting a “live” wire may make
exposed metal parts of the power tool “live” and could
give the operator an electric shock.
k.Position the cord clear of the spinning accessory.
If you lose control, the cord may be cut or snagged
and your hand or arm may be pulled into the spinning
l. Never lay the power tool down until the accessory has
d.Use special care when working corners, sharp edges
etc. Avoid bouncing and snagging the accessory.
Corners, sharp edges or bouncing have a tendency to
snag the rotating accessory and cause loss of control
or kickback.
e.Do not attach a saw chain woodcarving blade or
toothed saw blade. Such blades create frequent
kickback and loss of control.
Kickback is the result of power tool misuse and/or
incorrect operating procedures or conditions and can
be avoided by taking proper precautions as given below.
a.Do not “jam” the cut-off wheel or apply excessive
pressure. Do not attempt to make an excessive depth
of cut. Overstressing the wheel increases the loading
and susceptibility to twisting or binding of the wheel
in the cut and the possibility of kickback or wheel
b.Do not position your body in line with and behind
the rotating wheel. When the wheel, at the point of
operation, is moving away from your body, the possible
kickback may propel the spinning wheel and the power
tool directly at you.
c.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 cutoff 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
d.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.
e.Support panels or any oversized workpiece to
minimize the risk of wheel pinching and kickback.
Large workpieces tend to sag under their own weight.
Supports must be placed under the workpiece near the
line of cut and near the edge of the workpiece on both
sides of the wheel.
f. 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.
14 17 20 23 26 29
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your
mains-operated (corded) power tool or battery-operated
(cordless) power tool.
power tool. Distractions can cause you to lose control.
person using only identical replacement parts. This will
ensure that the safety of the power tool is maintained.
13 16 19 22 25 28
Always wear hearing protection. The effects of
noise can cause hearing loss.
Vibration total values (triaxial vector sum) determined
according to EN 60745
Surface vibration emission value ah,AG= 22.2 m/s2
Grinding Uncertainty K = 1.5 m/s2
The declared vibration total value may also be used in a
preliminary assessment of exposure.
protected supply. Use of an RCD reduces the risk of
electric shock.
a.Power tool plugs must match the outlet. Never modify
the plug in any way. Do not use any adapter plugs with
earthed (grounded) power tools. Unmodified plugs and
matching outlets will reduce risk of electric shock.
b.Avoid body contact with earthed or grounded surfaces,
such as pipes, radiators, ranges and refrigerators.
There is an increased risk of electric shock if your body
is earthed or grounded.
c.Do not expose power tools to rain or wet conditions.
Water entering a power tool will increase the risk of
electric shock.
d.Do not abuse the cord. Never use the cord for carrying,
pulling or unplugging the power tool. Keep cord away
from heat, oil, sharp edges or moving parts. Damaged
or entangled cords increase the risk of electric shock.
e.When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of a cord
suitable for outdoor use reduces the risk of electric
f. If operating a power tool in a damp location is
unavoidable, use a residual current device (RCD)
a.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
b.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.
c.Disconnect the plug from the power source and/or the
battery pack from the power tool before making any
adjustments, changing accessories, or storing power
tools. Such preventive safety measures reduce the risk
of starting the power tool accidentally.
d.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.
e.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.
f. Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges are
less likely to bind and are easier to control.
g.Use the power tool, accessories and tool bits etc.
in accordance with these instructions, 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.
a.Maintain a firm grip on the power tool and position your
body and arm to allow you to resist kickback forces.
Always use auxiliary handle, if provided, for maximum
control over kickback or torque reaction during
start-up. The operator can control torque reactions or
kickback forces, if proper precautions are taken.
b.Never place your hand near the rotating accessory.
Accessory may kickback over your hand.
c.Do not position your body in the area where power tool
will move if kickback occurs. Kickback will propel the
tool in direction opposite to the wheel’s movement at
the point of snagging.
a.Be aware that wire bristles are thrown by the brush
even during ordinary operation. Do not overstress the
wires by applying excessive load to the brush. The wire
bristles can easily penetrate light clothing and/or skin.
b.If the use of a guard is recommended for wire brushing,
do not allow any interference of the wire wheel or
brush with the guard. Wire wheel or brush may expand
in diameter due to work load and centrifugal forces.
EC-Declaration of conformity
We, the undersigned Batavia GmbH, Blankenstein 180,
NL-7943PE Meppel, declare by our own responsibility that
the product Angle Grinder, Item-No 7060533, Model Nr.
TAG-115-1 Is according to the basic requirements, which
are defined in the European Directives Electromagnetic
Compatibility 2004/108/EC (EMC).
Is according to the basic requirements, which are defined
in the European Directives, European Machinery Directive
For the evaluation of conformity, the following
harmonized standards were consulted:
EN 60745-1: 2009+A11, EN 60745-2-3: 2011,
EN 55014-1:2006/A2:2011,
EN 55014-2:1997/A2:2008,
EN 61000-3-2:2006/A1:2009, EN 61000-3-3:2008
Meppel, 01 september 2011
15 18 21 24 27 30
a.Have your power tool serviced by a qualified repair
a.Use only wheel types that are recommended for your
power tool and the specific guard designed for the
selected wheel. Wheels for which the power tool was
not designed cannot be adequately guarded and are
b.The guard must be securely attached to the power
tool and positioned for maximum safety, so the least
amount of wheel is exposed towards the operator. The
guard helps to protect operator from broken wheel
fragments, accidental contact with wheel and sparks
that could ignite clothing.
c.Wheels must be used only for recommended
applications. For example: do not grind with the side
Meino Seinen, QA Representative
Batavia GmbH, Blankenstein 180,
7943 PE Meppel, Netherlands
22/06/2004 1:50:15 AM
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