Clarke X-Pro CAT203 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 - ISS 1
3” CUT-OFF TOOL
MODEL NO: CAT203
PART NO: 3120520

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INTRODUCTION
Thank you for purchasing this CLARKE Cut-Off 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.
Please keep these instructions in a safe place for future reference.
SPECIFICATIONS
Model Number CAT203
Dimensions (L x W x H) 205 x 85 x 72 mm
Weight 0.79 kg
Disc Size (dia & thickness) 3” x 1/16”
Disc Bore Size 3/8”
Air Inlet Size 1/4“BSP (female)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 5 cfm average (no-load)
No Load Speed 20000 rpm @ 90psi
Speed settings 1 - 9000 rpm
2 - 15000 rpm
3 - 17000 rpm
4 - 20000 rpm
Sound Pressure Level (LpA dB) 84 dB(A)
Sound Power Level (LwA dB) 95 dB(A)
Vibration Levels 3.2 m/s2

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GENERAL SAFETY RULES
THE WORK ENVIRONMENT
1. ALWAYS keep the work area clean and tidy.
2. ALWAYS 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 AIR POWERED 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, CO2, combustible gases or any type of bottled gas as a
source of power for the tool.
6. DO NOT connect the air supply hose with your finger on the trigger.
7. DO NOT exceed the maximum pressure for the tool of 90 psi / 6.2 bar.
8. ALWAYS check hoses for leaks or worn condition before use, and ensure
that all connections are secure.
9. DO NOT use the tool for any purpose other than described in this manual.
10. ALWAYS keep the air supply hose away from heat, oil and sharp edges.
11. DO NOT fit the tool to any stand or clamping device that may damage it.
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.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• The tool will be left unattended.
• Moving to another work area.
14. NEVER use the tool if it is defective or operating abnormally.
15. Avoid damaging the tool by applying excessive force.
16. ALWAYS maintain the tool with care for the best and safest performance.
17. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
18. DO NOT force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
19. 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.
20. NEVER carry the tool by the air supply hose.
21. NEVER carry the tool with your finger on the trigger.
22. 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.
USE OF CUTTING DISCS
1. NEVER use cracked or chipped cutting discs.
2. NEVER use non-reinforced cutting discs.
3. NEVER use the cut off tool without disc guard in place.
4. NEVER use the side of the cutting disc for grinding.
5. Only use for cutting operations.

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COMPRESSED AIR REQUIREMENTS
A typical air line layout is shown below. 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.
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.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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OVERVIEW
When opening the carton for the first time, check against the above that all
the items are present. Any damage or deficiency should be reported to your
CLARKE dealer immediately
1 Disc Retaining Washer 6 Wrench
2Trigger 7HexKey
3 Air Exhaust Deflector 8 Inlet adaptor
4 Speed Control 9 3”dia, 1/16” thick 3/8” bore metal
cutting disc
5 Air Inlet Note: a pack of 10 discs is included

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BEFORE USE
CONNECTING THE AIRLINE
1. Remove the plastic blanking plug
from the air inlet connection.
2. Pour 2-3 drops of CLARKE airline oil
into the oil filling port. This should
be done regardless of whether or
not a lubricated air supply is to be
used.
3. If required, connect an in-line mini
oiler to the tool.
• A mini oiler helps to prolong the
life of any air tool.
4. Connect a suitable hose as shown or use the inlet adaptor supplied, to
connect directly to the hose.
5. Connect the other end of the hose to the compressor.
• PTFE tape may be useful for sealing threaded connections.
6. Turn on the air supply and check for air leaks. Rectify any found before
proceeding.
7. If using a mini oiler, place a sheet of paper next the exhaust port and
squeeze the trigger for approximately 30 seconds. The oil volume is
correctly set when a light stain of oil can be seen on the paper. Excessive
oil should be avoided.
Your air tool is now ready for 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.

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INSTALLING THE CUTTING DISC
1. Ensure the disc being fitted has a speed rating greater than 20,000 rpm
which is the maximum speed of the tool.
2. Install the disc and retaining
washer using the spanner and hex
key supplied.
NOTE: The disc must be fitted with
the metal facing touching
the retaining washer.
IMPORTANT: The use of parts other
than CLARKE replacement parts may
result in safety hazards, decreased
tool performance and may
invalidate your warranty.
• Replacement cutting discs are available from your CLARKE dealer,-
(Part number 3110731).
SETTING THE SPEED
1. Set the tool speed by rotating the
control to one of the four settings.
• The graduations on the speed
control indicate the speed
setting when aligned with the
reference mark on the air inlet.
• Speeds available are: (+/-10%)
19,000 rpm
215,000 rpm
317,000 rpm
420,000 rpm

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OPERATING THE TOOL
1. Use your thumb to slide the
throttle locking lever forward at
the same time as squeezing the
trigger against the body of the
tool.
• Allow the tool to run up to full
speed for a couple of seconds
before offering the disc to the
work piece.
2. Apply a steady, even pressure. Do
not force the tool.
3. Too much pressure can cause the disc to break and may shorten the life of
the tool.
4. Release the trigger to stop the tool.
• The tool will continue to rotate briefly after the trigger has been
released.
5. ALWAYS ensure the tool has stopped before putting it down.
SETTING THE AIR EXHAUST DEFLECTOR
The direction of the exhaust air
leaving the tool can be adjusted by
rotating the air exhaust deflector.
Twist the air exhaust deflector sleeve
to direct the air as required to deflect
air away from the workpiece or
operator.
DISCONNECTING THE AIR SUPPLY
1. DO NOT disconnect the air hose until the supply is isolated at a shut-off
valve.
2. Once the pressure has been isolated, disconnect the air supply hose from
the air tool.
3. Shut down the compressor at the end of the work session.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
tool.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
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.
Tool runs slowly. Air flows
weakly from exhaust.
1. Motor parts jammed
with gum/dirt.
2. Regulator in closed
position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
cleanliness and clean out
if necessary
2. Adjust regulator to open
position.
3. Operate tool in short
bursts.
Tool will not run. Air flows
freely from exhaust.
1. Motor vanes stuck
due to buildup of
foreign material.
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.
Tool will not shut off. 1. Throttle O-rings
damaged or ill-fitting
in seat.
1. Return to CLARKE dealer
for repair.

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MAINTENANCE
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 in-
line mini oiler is not used, this procedure should be repeated after every
two to three hours of use.
CLEANING
1. Check the air inlet screen filter for
blockage and clean if necessary
2. Keep the body of the tool clean
and free from debris.
3. 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.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE PERFORMING ANY CLEANING OR MAINTENANCE.

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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 the air supply, clean and store in a safe, dry
place. When storing, replace the blanking plug to the airline inlet.
Avoid storing the tool in environments where the temperature is below 0oC
ACCESSORIES
Replacement cutting discs are available from your CLARKE dealer,-(Part
number 3110731).
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.
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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DECLARATION OF CONFORMITY

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COMPONENT PARTS

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COMPONENT PARTS LIST
No Description No Description
1 Main housing 24 Bearing
2 Bushing 25 Rear plate
3 Brass sleeve 26 Steel ball
4 O-ring 27 Rotor
5 Trigger 28 Rotor blade
6 Lever 29 Cylinder
7 Spring 30 Bushing
8 Top pin 31 Front plate
9Triggerpin 32Pin
10 Air inlet 33 Steel ball
11 Spring 34 Bearing
12 Pin 35 Collet jacket
13 O-ring 36 Fixing ring
14 Air regulator 37 Cushion
15 O-ring 38 Gasket
16 Muffler 39 Metal guard
17 O-ring 40 Circlip
18 O-ring 41 Cutting wheel
19 Valve stem 42 Spacer
20 Spring 43 Set screw
21 O-ring 44 Hex key
22 Set screw 45 Wrench
23 Sealing ring