Clarke CAT 219, 3110473 User guide

3/8”REVERSIBLE AIR DRILL

MODEL NO: CAT219

PART NO: 3110473

OPERATING & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0922 - Rev 1

INTRODUCTION

Thank you for purchasing this CLARKE Reversible Air Drill.

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.

SPECIFICATIONS

MODEL NO CAT 219

Min. Hose Size (ID) 3/8” (10 mm)

Chuck Size 1.5 - 10 mm (max 3/8”)

Operating Air Pressure 90 psi (6.2 bar)

Air Consumption 5.5 cfm

Max No-load Speed 1400 rpm

Air Inlet Size 1/4“BSP

Sound Pressure Level (LpA dB) 86 dB(A)

Sound Power Level (LwA dB) 97 dB(A)

Vibration Levels

Dimensions (L x W x H) 215 x 40 x 95 mm

Weight 1.16 kg

1.818 m/s

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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 affect your statutory rights.

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GENERAL SAFETY RULES

CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

WORK ENVIRONMENT

1. Keep the work area clean and tidy.

2. Dress appropriately - DO NOT wear loose clothing or jewellery. Tie long hair
out of the way.

3. Keep children and visitors away - DO NOT let children handle the drill.

4. DO NOT operate the drill where there are flammable liquids or gases.

5. Keep the air supply hose away from heat, oil and sharp edges.

6. DO NOT fit the drill to any stand or clamping device that may damage it.

PRODUCT USE

1. Stay alert and use common sense - DO NOT operate the drill when you are
tired or under the influence of alcohol, drugs or medication.

2. ALWAYS wear eye protectors when using the drill - eye protectors must
provide protection from flying particles from the front and the side.

3. ALWAYS wear ear protectors when using the drill.

4. DO NOT overreach - keep proper footing and balance at all times.

5. NEVER use any type of bottled gas as a source of power for the drill.

6. DO NOT connect the air supply hose with your finger on the trigger of the
drill.

7. DO NOT exceed the maximum pressure for the drill 90 psi / 6.2 bar.

8. Check hoses for leaks or worn condition before use and ensure that all
connections are secure.

9. DO NOT use the drill for any other purpose than that described in this
manual.

10. DO NOT carry out any alterations or modifications to the drill.

11. ALWAYS disconnect from the air supply when:

• Performing any maintenance

• The drill is not in use.

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• The drill will be left unattended.

• Moving to another work area.

• Passing the drill to another person.

12. NEVER use the drill if it is defective or operating abnormally.

13. The drill should be serviced at regular intervals by qualified service
personnel.

14. AVOID damaging the drill for example by applying excessive force.

15. ALWAYS maintain the drill with care. Keep it clean for the best and safest
performance.

16. Quick change couplings should not be located at the drill. They add
weight and could fail due to vibration.

17. DO NOT force or misuse the drill. It will do a better and safer job at the rate
for which it was designed.

18. This drill vibrates with use. Vibration may be harmful to your hands or arms.
Stop using the drill. if discomfort, a tingling feeling or pain occurs. Seek
medical advice before resuming use.

DRILL SAFETY PRECAUTIONS

1. ALWAYS make sure the work surface is free from nails and other foreign
objects.

2. After changing bits and accessories or making adjustments, make sure the
chuck is securely tightened and that the chuck key has been removed.

3. ALWAYS check bits for damage before each use. Damaged bits or other
accessories can break during use and cause serious injury.

4. NEVER use dull or damaged bits. Sharp bits must be handled with care.
Damaged bits can snap during use. Dull bits require more force possibly
causing the bit to break.

5. Use of a dust collection system reduces dust-related hazards.

6. Maintain a firm grip on the tool and position your body and arms to allow
you to resist kickback forces. Kickback will propel the tool in the direction
opposite to the tool's movement at the time of snagging.

7. Use metal and voltage detectors to locate hidden electric. water or gas
lines. Avoid touching live components or conductors.

8. Before drilling, check that there is sufficient clearance for the drill bit under
the workpiece.

9. If you are interrupted when operating the drill, switch off the tool before
looking up.

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TRANSPORT

1. NEVER carry the drill by the air supply hose.

2. NEVER carry the drill with your finger on the trigger.

STORAGE

1. When not in use the drill must be disconnected from the air supply and
stored in a dry place out of the reach of children (preferably in a locked
cabinet).

2. AVOID storing the drill in environments where the temperature is below 0

PRODUCT OVERVIEW

o

C

NO DESCRIPTION NO DESCRIPTION

1 Grease nipple 4 Forward/reverse control

2 Trigger 5 Chuck

3 1/4” BSP female air inlet 6 Airline connector

CONTENTS

• 1 x 3/8” Reversible air drill

• 1 x Chuck Key

• 1 x Air inlet screw-in connector

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THE COMPRESSED AIR SUPPLY

AIR SUPPLY REQUIREMENTS

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLY.

A typical air line layout is shown above. If an automatic in-line filter/regulator is
used, it will keep the tool in good condition, but should be regularly checked
and topped up with oil. SAE 10 oil should be used, and the lubricator adjusted
to approx 2 drops per minute.

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Use only clean, dry, regulated compressed air as a power source.

Air compressors used with the tool must comply with the appropriate UK/EU
Safety Directives.

A build-up of moisture or oil in the air compressor will accelerate wear and
corrosion in the tool. ensure any moisture is drained from the compressor daily
and the inlet filter is kept clean.

If an unusually long air hose (over 8 metres), is required, the line pressure or the
hose inside diameter may need to be increased.

The air hose must be rated at least 150% of the maximum operating pressure of
the tool.

The minimum hose diameter should be 3/8”(10mm) ID and fittings should have
the same internal dimensions.

Never exceed the maximum operating pressure for the tool. It is
recommended that air pressure to this tool does not exceed 90 psi at the tool
when running. Higher pressures and unclean air will shorten the life of the tool
due to faster wear and is a possible safety hazard.

BEFORE USE

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND COMPRESSED AIR SUPPLY.

NOTE: Ensure the compressor is turned off.

1. If required, connect an in-line mini
oiler to the tool.

• A mini oiler helps to prolong the

life of the air tool. Remove the
oil fill screw from the side of the
mini oiler and fill with Air-line Oil
available from your CLARKE
dealer. Replace the screw
before using the tool.

2. If a mini-oiler is not being used, run
a few drops of oil through the tool before use. It can be entered through
the inlet strainer or via the hose at the nearest connection to the air supply.

3. Remove the travel plug from the air inlet and connect a suitable hose as
shown.

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4. Connect the other end of the hose to the compressor.

5. Turn on the air supply at low pressure and check for air leaks. Rectify any
found before proceeding.

6. Your air tool is now ready for use.

• You can fit a whip hose with a quick fit coupling if required

(available from your dealer).

OPERATION

INSERTING/REMOVING THE DRILL BIT

1. Open the chuck jaws by inserting
the chuck key in one of the holes
in the chuck and turning it as
shown.

2. Make sure that the head of the
chuck key is located on the barrel
of the chuck.

3. Turn the chuck key until the chuck
jaws are open sufficiently to take
the drill bit.

4. Place the drill shank into the jaws
of the chuck.

5. Close the chuck jaws and tighten
to grip the drill bit by turning the
chuck key as shown.

6. Make sure that the chuck jaws are
fully closed and that the drill bit is
held firmly.

7. Your air drill is now ready for use.

OPERATING THE AIR DRILL

WARNING: MAKE SURE THAT THE CHUCK KEY HAS BEEN REMOVED
BEFORE USING THE DRILL.

1. Squeeze the trigger to start the drill.

• Lightly position the bit on the workpiece & gently squeeze the trigger.

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• Once the drill is cutting and up to speed, apply a steady pressure to

drill into the workpiece.

2. Release the trigger to stop.

3. Always ensure the drill has stopped before putting it down.

SETTING FORWARD/REVERSE

1. Ensure the drill is stationary before
selecting forward or reverse.

2. Set the drill to Forward (drilling)
mode by pressing the button in
and turning a quarter of a turn.

3. Revere this action or Reverse
operation.

SAFE DRILLING WITH THE AIR DRILL

CAUTION: IMMEDIATELY RELEASE THE TRIGGER IF THE DRILL BIT BECOMES
STUCK OR JAMMED, THE TOOL'S TORQUE CAN TWIST YOUR ARM AND
CAUSE AN INJURY. THE TOOL MAY TWIST OUT OF YOUR GRIP AND CAUSE
AN INJURY TO YOURSELF OR A BYSTANDER.

1. Verify the drill's rotation before starting the drill.

2. A loose or mismatched bit may be ejected by the tool, causing an injury to
the user or a bystander. It may also fail to penetrate the material as the
point may move around under pressure, damaging the workpiece.

• Ensure the bit shank size matches the tool's chuck.

• Tighten the chuck so the shank is tightly held with no room to move.

3. Always hold the tool firmly when switching on. The reaction to the motor's
torque may cause the tool to twist as it accelerates to full speed.

4. DO NOT use drill as a router or try to elongate or enlarge holes by
twis ting the drill. Drill bits can break and can cause injury.

5. DO NOT apply side pressure on the bit unless it is designed for such a
purpose. The bit may bind or break.

6. NEVER attempt to change the rotation direction while the tool is running.
Be sure the switch is OFF and the motor has completely stopped before
changing the rotation direction.

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DISCONNECTING THE AIR SUPPLY

DO NOT disconnect the air supply hose until the compressor has been shut
down and the compressed air released.

1. Refer to the compressor instruction manual for the procedure to shut down
and release the compressed air.

2. Once the pressure has been released, disconnect the air supply hose from
the air drill.

3. Store the tool safely in its box in a dry, secure environment.

TROUBLESHOOTING

SYMPTOM PROBLEM SOLUTION

Tool runs at normal
speed but slows down
under any load.

Tool runs slowly. Air flows
weakly from exhaust.

Tool will not run. Air flows
freely from exhaust.

Tool will not shut off. 1. Throttle O-rings

1. Excessive pressure on
drill.

2. Motor parts worn.

3. Worn or sticking
mechanism due to
lack of lubricant.

1. Motor parts jammed
with gum/dirt.

2. Regulator in closed
position.

3. General airflow
blocked by dirt.

1. Motor vanes stuck
due to buildup of
foreign material.

damaged or ill-fitting
in seat.

1. Reduce the force
applied to the drill.

2. Return to your CLARKE
dealer for repair.

3. Drip air tool lubricating
oil into air inlet. Allow oil
to soak moving parts
before using.

1. Examine inlet air filter for
cleanliness.

2. Adjust regulator to open
position.

3. Operate tool in short
bursts.

1. Disconnect air supply
and rotate tool assembly
manually.

2. Try operating tool in
short bursts.

3. Tap motor housing gently
with a rubber mallet.

4. Drip a few drops of air
tool oil into air inlet to
soak moving parts.

1. Return to your CLARKE
dealer for repair.

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MAINTENANCE

WARNING: MAKE SURE THAT THE DRILL IS DISCONNECTED FROM THE AIR
SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

DAILY

1. Before use, drain water from the compressor air tank and air line.

2. Pour a few drops of airline oil into the tool air inlet. This should be carried out
regardless of whether or not an in-line mini oiler is used. If an in-line mini oiler
is not used, this procedure should be repeated after every two to three
hours of use.

WEEKLY

1. Check the air inlet screen filter for
blockage and clean if necessary.

2. Applying grease to the head
assembly is recommended to
prolong the life of the tool. Press
your grease gun nozzle against
the grease nipple on the side of
the drill to inject a shot of grease.
Run the tool for a few moments to
distribute the grease internally.

CLEANING

1. Keep the body of the tool clean
and free from debris.

2. Grit or gum deposits in the tool may also reduce efficiency. This condition
can be corrected by cleaning the air strainer and flushing out the tool with
gum solvent oil, or failing this, the tool should be disassembled, thoroughly

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cleaned, dried and reassembled.

3. After extensive use, remove the inlet screen filter and flush out the
mechanism with gum solvent oil or an equal mixture of SAE No10 oil and
paraffin. Allow to dry before use.

5. If the tool runs erratically or becomes inefficient, and the air supply is of
good quality, it may be necessary to dismantle the air motor and replace
worn or damaged parts. You may prefer to take the drill to your CLARKE
dealer if internal maintenance is required.

This air tool has been designed to give long and trouble free service. If,
however, having followed the instructions in this booklet carefully (refer to
page 10 - Troubleshooting), you encounter problems, take the unit to your
local CLARKE dealer.

PERFORMANCE

Please note that factors other than the tool may effect its operation and
efficiency such as reduced compressor output, excessive drain on the airline
moisture or restrictions in the air-line, or the use of connectors of improper size
or poor condition which will reduce air supply.

STORAGE

If the tool is to be stored, or is idle for longer than 24 hours, run a few drops of
air line oil into the air inlet, and run the tool for 5 seconds in order to lubricate
the internal parts.

When not in use, disconnect from air supply, clean & store in a safe, dry place.

ACCESSORIES

A wide range of accessories is available including filter/regulators, lubricators,
high-pressure hoses (5 to 50 metres) etc.

Contact your CLARKE dealer for further information or CLARKE International
Service Department on 01992 565333.

**CLARKE Airline Oil (part no. 3050825) is available from your CLARKE dealer.

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DECLARATIONS OF CONFORMITY

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COMPONENT PARTS

NO ITEM NO ITEM

1Screw 26Pin

2 Chuck Assembly 27 Cylinder

3 Circlip 28 Rear Cylinder Head

4 Woodruffe Key 29 Sealing Gasket

5 Drive Shaft 30 Main Housing

6 Bearing 31 Sealing Gasket

7 Bevel Gear 32 Pin

8 Bearing 33 Sealing Cover

9 Circlip 34 Muffler

10 Angled Head 35 O-ring

11 Grease Nipple 36 Gasket

12 Bevel Gear 37 Air Inlet

13 Bearing 38 Trigger

14 Gear Shift 39 Bolt

15 Locating Ring 40 Valve Stem

16 Planetary Cage 41 O-ring

17 Pin 42 O-ring

18 Planetary Gear 43 Valve Bush

19 Gear Ring 44 Spring

20 V-Gasket 45 O-ring

21 Bearing 46 Locating Tab

22 Sleeve Connecting Nut 47 Sealing Screw

23 Front Cylinder Head 48 Spring

24 Rotor 49 Reverse Regulator Sleeve

25 Rotor Blade 50 Reverse Control Knob

51 Chuck Key

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COMPONENT PARTS

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