Clarke CAT100 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0613
REVERSIBLE AIR DRILL
MODEL NO: CAT100
PART NO: 3110856

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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.
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. Please pay particular attention to all sections of these instructions
that display warning symbols and notices.
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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GENERAL SAFETY RULES
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.
5. Keep the air supply hose away from heat, oil and sharp edges.
6. Do not fit the tool to any stand or clamping device that may damage it.
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 tool for any other purpose than that described in this
manual.
10. Do not carry out any alterations or modifications to the tool.
11. Always disconnect from the air supply when:
• Performing any maintenance
• The drill 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 drill will be left unattended.
• Moving to another work area.
• Passing the drill to another person.
12. Never use the impact wrench 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 of any
kind.
15. ALWAYS maintain the tool with care. Keep it clean for the best and safest
performance.
16. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
17. DO NOT force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
18. Do not remove any labels. Damaged labels should be replaced.
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.
TRANSPORTATION
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 0oC.

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OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Chuck 4 Trigger Lock
2 Trigger 5 1/4” BSP (Female Air Inlet)
3Forward/ReverseSwitch
2

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THE COMPRESSED AIR SUPPLY
AIR SUPPLY REQUIREMENTS
• Use only clean, dry, regulated compressed air as a power source.
• Air compressors used with the impact wrench 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 impact wrench. 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 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.
• The minimum hose diameter should be 5/16”(8mm) ID and fittings
should have the same internal dimensions.
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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• 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
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. 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
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.)
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.
Oil Fill Screw
Mini Oiler

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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 bit in the jaws of the
chuck as far as it will go.
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.
Drill bit
Chuck jaws Close
Open
Chuck
key
jaws
jaws
Barrel

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OPERATION
OPERATING THE AIR DRILL
1. Squeeze the trigger switch to start
the drill.
2. Wait until the drill is running at its
maximum speed before applying
it carefully to the workpiece.
3. Release the trigger switch to stop
the drill.
4. To change the direction of rotation
move the lever on the left side of
the drill body from F to R.
5. Always ensure the drill has stopped before putting it down.
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.
Store the tool safely in its box in a dry, secure environment.
WARNING: MAKE SURE THAT THE CHUCK KEY HAS BEEN REMOVED
BEFORE USING THE DRILL.

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MAINTENANCE
DAILY
• Before use, drain water from the air tank, air line and compressor.
• 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
• Check the air inlet screen filter
for blockage and clean if
necessary.
CLEANING
• Keep the body of the impact
wrench clean and free from
debris. Grit or gum deposits in
the tool may reduce efficiency.
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 tool. Such servicing and
repair work should be carried out by qualified service technicians.
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.
Grit or gum deposits inside the tool may also reduce its efficiency. This
condition can be corrected by cleaning out the air strainer and flushing out
the tool with gum solvent or oil, or failing this, the motor may require
dismantling.
**Clarke Air Line Oil (part no. 3050825) is available from your CLARKE dealer .
WARNING: MAKE SURE THAT THE IMPACT WRENCH IS DISCONNECTED
FROM THE AIR SUPPLY BEFORE STARTING ANY CLEANING, OR
MAINTENANCE PROCEDURES.

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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 air supply, clean tool and 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.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
drill.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force
applied to the drill.
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.
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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PARTS LIST & DIAGRAM
No Description No Description
1 Screw 15 Cylinder
2 Drill Chuck 16 Motor Housing
3 Gear Housing 17 Trigger
4 Pin 18 Valve Spring
5 Ball Bearing 19 Throttle Valve
6 Planet Carrier 20 O-Ring
7PlanetGear 21O-Ring
8 Internal Gear 22 Reverse Valve
9 Ball Bearing 23 O-Ring
10 Bearing Housing 24 Reverse Valve Bush
11 End Plate 25 Pin
12 Rotor Body 26 Exhaust Deflector
13 Rotor Blade 27 Screw
14 Motor Pin 28 Air Inlet

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SPECIFICATION
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.
Model Number CAT100
Part Number 3110856
Min. Hose Size (ID) 8 mm
Chuck Size 1.5 - 10 mm (3/8”)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4 cfm
No Load Speed 1800 rpm @ 90psi
Air Inlet Size 1/4“ BSP
Sound Pressure Level (LpA dB) 94 dB(A)
Sound Power Level (LwA dB) 104 dB(A)
Vibration Levels 1.75 m/s2
Weight 1 kg

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DECLARATION OF CONFORMITY