Clarke CAT 98, 3110854 User guide

STRAIGHT DIE GRINDER

MODEL NO: CAT36B & CAT98

PART NO: 3110436 & 3110854

OPERATING & MAINTENANCE

INSTRUCTIONS

GC0615

INTRODUCTION

Thank you for purchasing this CLARKE air tool.

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.

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 its intended the purpose.

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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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 tool.

4. Do not operate the tool where there are flammable liquids or gases.

USE OF POWER TOOLS

1. Stay alert and use common sense - do not operate the air tool when you
are tired or under the influence of alcohol, drugs or medication.

2. Always wear eye protectors when using the tool - Eye protectors must
provide protection from flying particles from the front and the side.

3. Always wear ear protectors when using the air tool.

4. Do not overreach - Keep proper footing and balance at all times.

5. Never use oxygen, CO
source of power for the tool.

6. Do not connect the air supply hose with your finger on the trigger.

7. Do not fit the tool to any stand or clamping device that may damage it.

8. Do not exceed the maximum pressure for the tool of 90 psi / 6.2 bar.

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

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

11. Do not use the tool for any other purpose than that described in this
manual.

12. Do not carry out any alterations or modifications to the tool.

13. Always disconnect from the air supply when:

• Performing any maintenance.

• The tool is not in use.

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, combustible gases or any type of bottled gas as a

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• The tool will be left unattended.

• Moving to another work area.

• Passing the tool to another person.

14. Never use the tool if it is defective or operating abnormally.

15. The tool should be serviced at regular intervals by qualified service
personnel.

16. Avoid damaging the tool for example by applying excessive force.

17. Always maintain the tool with care. Keep it clean for the best and safest
performance.

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

19. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.

20. Do not remove any labels. Damaged labels should be replaced.

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

USE OF THE GRINDING TOOLS

1. Ensure that sparks and particles resulting from use do not create a hazard,
Use screens where appropriate.

2. Never bump the grinding stones onto the workpiece, or let it hit any other
objects while grinding.

3. Always allow the tool to run up to full operating speed before applying it to
the job.

4. Use clamps, or vices to hold the workpiece. Failure to secure the workpiece
could result in personal injury.

TRANSPORTATION AND STORAGE

1. Never carry the tool by the air supply hose.

2. Never carry the tool with your finger on the trigger.

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

4. Avoid storing the tool in environments where the temperature is below 0

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o

C.

COMPRESSED AIR 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.

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

• Air compressors used with the tool must comply with the appropriate

European Community 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 is required, (over 8 metres), 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.

• 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.

• 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.

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OVERVIEW

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NO DESCRIPTION NO DESCRIPTION

1 Moulded Storage Case 4 Male Snap Connector

2 Die Grinder 5 10 Grinding Stones (CAT36B only)

3 2 x Collet Wrenches 6 2 x Collets (1 already fitted to tool)

The CAT 36 Die Grinder is identical to the CAT98 other than in the body style.

The CAT36B Die Grinder KIt includes the accessories shown.

When opening the carton for the first time, check against the following list that
all the items are present. Any damage or deficiency should be reported to
your CLARKE dealer immediately

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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.

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 connector or via the hose
at the nearest connection to the air supply.

3. Connect a suitable hose as shown.

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

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

• PTFE tape may be helpful for

sealing threaded connections.

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 Clarke dealer).

INSTALLING THE COLLET

1. Select the grinding stone you require.

2. Three collets of different sizes are
provided. Select whichever fits
the shank of the stone you have
chosen.

• The larger collet is probably

already installed in the grinder.

3. If a different collet is to be used,
undo the screw cap completely
and pull out the collet from the
collet seat. Replace it with the
new collet and screw the cap loosely back on.

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FITTING THE GRINDING STONE

IMPORTANT: Never use chipped or cracked grindstones.

1. Slip the shank of the chosen stone
into the collet and tighten the
screw cap finger tight.

2. Place one wrench over the collet
seat to stop the tool from rotating.

3. Use the other wrench to fully
tighten the collet and grip the
stone in position as shown.

OPERATING THE DIE GRINDER

1. Use your thumb to slide the
throttle locking lever forward while
squeezing the trigger against the
body of the tool.

2. Do not use excess pressure on the
grinding stone as this will shorten
its life.

3. Release the trigger to stop the
grinder.

• The tool will continue to rotate

very briefly after the trigger has been released.

Always ensure the grinder has stopped before putting it down.

SETTING THE SPEED

1. Adjust the tool speed by setting
the air regulator on top of the tool
body using a suitable screwdriver.

DISCONNECTING THE AIR SUPPLY

1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released.

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

3. Once the pressure has been released, disconnect the air supply hose from
the tool.

STORAGE

If the tool is to be stored, or is idle for longer than 24 hours, run a few drops of
Clarke 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 tool and store in a safe, dry
place. When storing, ensure the blanking plug is replaced on the airline
connector once the airline is disconnected.

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MAINTENANCE

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

DAILY

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

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

WEEKLY

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

CLEANING

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

2. Grit or gum deposits inside the tool
may also reduce its efficiency. This
condition can be corrected by
cleaning out the air strainer inside
the air inlet, and flushing out the tool with gum solvent or oil, or failing this,
the motor may require dismantling. This is better left to your Clarke dealer.

SERVICE AND REPAIR

If the tool runs erratically or becomes inefficient although the air supply is in
good order, it may be necessary to dismantle the air motor and replace any
worn or damaged parts. Such servicing and repair work should be carried out
by a qualified service technician.

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.

**Clarke Air Line Oil (part no. 3050825) is available from your CLARKE dealer.

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Your Clarke air tool has been designed to give long and trouble free service. If,
however, having followed the instructions in this booklet carefully, you
encounter problems, take the unit to your local Clarke dealer.

STORAGE

If the tool is to be stored, or is idle for longer than 24 hours, run a few drops of
Clarke air-line oil into the air inlet, and depress the trigger in order to lubricate
the internal parts. When not in use, disconnect from air supply, clean and store
in a safe, dry place.

ACCESSORIES

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

Contact your Clarke dealer or Clarke International Service Department for
further information.

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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

1. Reduce the force
applied to the tool.

2. Return to 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 lubricating oil into air
inlet to soak moving parts

1. Return to Clarke dealer
for repair.

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SPECIFICATIONS

Model Number CAT36B & CAT98

Tool Weight 0.6 kg

Collet Capacity 1/8” - 1/4”

Air Inlet Size 1/4“BSP (female)

Minimum Hose Size 5/16” (8mm) dia

Operating Pressure 90 psi (6.2 bar)

Air Consumption 8 cfm average

No Load Speed 22000 rpm @ 90psi

Sound Pressure Level (LpA dB) 92 dB(A)

Sound Power Level (LwA dB) 105 dB(A)

Vibration Levels

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
machine’s data plate.

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

2.08 m/s

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COMPONENT PARTS

No Description No Description

1 Double-ended Spanner 17 Ball Bearing

2 Double-ended Spanner 18 Motor Housing

3 Collet Nut 19 Valve Screw

4 Collet 20 O-Ring

5 Housing Cap 21 O-Ring

6 Retainer 22 Air Regulator

7 Spindle 23 Spring

8n/a 24O-Ring

9 Ball Bearing 25 Throttle Valve

10 Front End Plate 26 n/a

11 Ball 27 Throttle Lever

12 Cylinder 28 Throttle Lever Pin

13 O-Ring 29 Exhaust Deflector

14 Rotor 30 O-Ring

15 Rotor Blade 31 Circlip

16 Rear Plate

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DECLARATION OF CONFORMITY

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