Clarke CAT123 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
GC1110
1/2” REVERSIBLE AIR DRILL
MODEL NO: CAT123
PART NO: 3110879

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INTRODUCTION
Thank you for purchasing this CLARKE product.
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 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.
ENVIRONMENTAL PROTECTION
Recycle unwanted materials instead of disposing of them as
waste. All tools, accessories and packaging should be sorted,
taken to a recycling centre and disposed of in a manner which is
compatible with the environment.

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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 air drill.
Make sure that any other persons in the work area are dressed suitably and
are wearing eye and ear protection.
4. Do not operate the drill where there are flammable vapours.
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.
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 protection when using the drill - Eye protectors must
provide protection from flying particles from the front and the side.
3. Always wear ear protection when using the drill.
4. Do not over reach - 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.
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 book.
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.
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 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 of any
kind.
15. Always maintain the drill with care. Keep it clean for 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. 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 should 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
Unpack and lay out the components, checking against the following list. Any
damage or deficiency should be reported to your CLARKE dealer
immediately.
• 1/2” Reversible Air Drill
• Male Snap Connector
• Bottle of Airline Oil
•ChuckKey
NO DESCRIPTION NO DESCRIPTION
1Chuck 4Handle
2 Trigger 5 Air hose connector
3 Forward/Reverse Switch

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• Side Handle
• Side Handle Clamping Ring
• Operators Manual (this document)
ACCESSORIES
A wide range of accessories are available, including Filter/Regulators, Airline
Lubricators, High Pressure Hoses (5 to 50 Metres), adaptors and connectors
etc.
Contact your CLARKE dealer for further information, or CLARKE International
Sales Department on 01992 565 333.

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COMPRESSED AIR LINES
AIR SUPPLY REQUIREMENTS
• Use only clean, dry, regulated compressed air as a power source.
• Air compressors used with the air drill 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 air drill. 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), line pressure
may need to be increased.
• Never exceed the maximum operating pressure for the air drill.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.
A typical airline layout is shown below. If an automatic in-line filter/regulator/
lubricator unit is used it will keep the tool in good condition, but should be
regularly checked and topped up with oil.
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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IMPORTANT: If a filter/lubricator unit is not used, the air tool should be
lubricated with 2 to 6 drops of oil, at least once a day or after 2 hours work,
depending upon the working environment. The oil can be inserted through
the airline connection point.
AIRLINE SAFETY
• Never exceed the maximum operating pressure for the tool. A
pressure of 90 psi with a flow of 16 cfm is required. Too high an air
pressure will shorten the life of the tool due to excessive wear.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.
BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the travel plug from the
airline socket.
2. Pour 2-3 drops of CLARKE airline oil
into the air inlet. This should be
done regardless of whether or not
a lubricated air supply is to be
used.
3. Connect a suitable hose to the air
drill as shown, using the adapter
supplied if required.
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
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
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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FITTING THE HANDLE
The CAT123 is supplied with a
removable side handle. To install it
proceed as follows.
1. Slide the clamping ring over the
body of the drill.
2. Screw the handle onto the
threaded part of the clamping ring
until the handle assembly is tight.
The handle can be located at any
position around the drill by loosening
the handle grip and re-tightening to secure in position.
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 pressure released.
1. Refer to the compressor instruction book for the procedures to shut down
and release the compressed air.
2. Once the pressure has been released, disconnect the air supply hose from
the air drill.
STORAGE
1. Store the air drill safely in a dry, secure environment.
2. If the tool is not to be used for longer than 24 hours, run a few drops of
CLARKE airline oil into the air inlet and run the tool for a few seconds to
ensure that the oil has been well distributed throughout the tool.
3. When storing, ensure the blanking plug is replaced on the airline inlet
connector once the airline has been disconnected.
WARNING: MAKE SURE THAT THE CHUCK KEY HAS BEEN REMOVED
BEFORE USING THE DRILL.

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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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MAINTENANCE
DAILY
• Drain any water from the air tank, airline, and compressor.
• Pour a few drops of CLARKE air line oil, into the air inlet. This should be
carried out regardless of whether or not an air line lubricator is used. If an
airline lubricator is not used, this procedure should be repeated after
every two to three hours of use.
WEEKLY
• Check the air inlet screen filter
and clean if necessary. It may
be necessary to unscrew the air
inlet connector to achieve this.
CLEANING
• Keep the body of the air drill
clean and free from debris, grit
or gum deposits in the tool may
reduce efficiency.
• 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.
SERVICE AND REPAIR
• Major servicing and repairs should be carried out by a qualified service
technician.
PERFORMANCE
• Please note that factors outside the tool may effect its operation and
efficiency such as reduced compressor output, excessive drain on the
airline, moisture or restrictions in the 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 DRILL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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SPECIFICATIONS
Feature Specification
Model Number CAT123
Min. Hose Size (ID) 10 mm
Average Air Consumption 16 cfm
Operating Air Pressure 90 psi (6.2 bar)
Chuck Size 1.5 - 13 mm
Maximum Speed 700 rpm
Sound Pressure Level (LpA dB) 81.9 dB(A)
Sound Power Level (LwA dB) 92.9 dB(A)
Vibration Levels 1.2 m/s2 at the Main Handle
K = 34.44
Dimensions (L x W x H) 208 x 49 x 150 mm
Weight 1.8 kg

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PARTS LIST & DIAGRAM
No Description Part No No Description Part No
1 Housing RONCAT12301 18 Cylinder RONCAT12318
2 Roll Pin RONCAT12302 19 Rotor Blade RONCAT12319
3 Exhaust Deflector RONCAT12303 20 Steel Wire RONCAT12320
4 O-Ring RONCAT12304 21 Rotor RONCAT12321
5 Air Inlet RONCAT12305 22 Front Plate RONCAT12322
6 Valve Stem RONCAT12306 23 Gear Wheel RONCAT12323
7 O-Ring RONCAT12307 24 Idle Gear RONCAT12324
8 O-Ring RONCAT12308 25 Idler Gear Pin RONCAT12325
9 O-Ring RONCAT12309 26 Gear Shaft RONCAT12326
10 Bushing RONCAT12310 27 Wheel Pin RONCAT12327
11 Reverse Gear RONCAT12311 28 Washer RONCAT12328
12 O-Ring RONCAT12312 29 Gear Shaft RONCAT12329
13 Spring RONCAT12313 30 Bearing RONCAT12330
14 Trigger RONCAT12314 31 Clamp Nut RONCAT12331
15 O-Ring RONCAT12315 32 Washer RONCAT12332
16 Bearing RONCAT12316 33 Chuck RONCAT12333
17 End Plate RONCAT12317 34 Chuck Screw RONCAT12334

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DECLARATION OF CONFORMITY