Clarke X-Pro CAT207 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 -ISS 1
3/8”AIR DRILL
MODEL NO: CAT207
PART NO: 3120524

2
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INTRODUCTION
Thank you for purchasing this CLARKE 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.
Please keep these instructions in a safe place for future reference.
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.
Model Numbers CAT207
Min. Hose Size (ID) 9.5 mm (3/8”)
Chuck Size 1.5 - 10 mm
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4.5 cfm (average)
Max No Load Speed 20000 rpm @ 90psi
Speed settings Setting 1 - 11,000 rpm
Setting 2 - 15,000 rpm
Setting 3 - 18,000 rpm
Setting 4 - 20,000 rpm
Air Inlet Size 1/4“BSP Female
Sound Pressure Level (LpA dB) 76 dB(A)
Sound Power Level (LwA dB) 87 dB(A)
Vibration Levels 1.87 m/s2
Vibration Uncertainty K 1.5
Dimensions (L x W x H) 216 x 71 x 43 mm
Weight 0.7 kg

3
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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. ALWAYS 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.
USE OF AIR POWERED TOOLS
1. ALWAYS 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 protection 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.
7. DO NOT exceed the maximum pressure for the drill 90 psi / 6.2 bar.
8. ALWAYS check hoses for leaks or worn condition before use and ensure
that all connections are secure.
9. ALWAYS keep the air supply hose away from heat, oil and sharp edges.
10. DO NOT use this drill for any other purpose than that described in this
manual.
11. DO NOT fit this drill to any stand or clamping device that may damage it.
12. DO NOT carry out any alterations or modifications to this drill.
13. 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.

4
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
• The drill will be left unattended.
• Moving to another work area.
14. DO NOT use the drill if it is defective or operating abnormally.
15. ALWAYS avoid damaging the drill by applying excessive force.
16. ALWAYS maintain the drill with care for the best and safest performance.
17. Quick change couplings should not be located at the air tool. They add
weight and could fail due to vibration.
18. DO NOT force or misuse the drill. It will do a better and safer job at the rate
for which it was designed.
19. 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.
20. DO NOT carry the drill by the air supply hose.
21. DO NOT carry the drill with your finger on the trigger.

5
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPRESSED AIR REQUIREMENTS
A typical air line layout is shown below. If an automatic in-line filter/regulator is
used, it will keep the air 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 A COMPRESSED AIR SUPPLY.

6
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
Never exceed the maximum operating pressure for the tool. It is
recommended that air pressure does not exceed 90 psi at the tool when
running. Higher pressures and unclean air will shorten the life of any air 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 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 tools used. 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 drill.
OVERVIEW
1 Chuck 5 Air Exhaust Deflector
2 Trigger 6 Male inlet connector
3 1/4” BSP female air inlet 7 Chuck Key
4 Speed Selector Switch

7
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
BEFORE USE
When opening the carton, check that all the items are present. Any damage
or deficiency should be reported to your CLARKE dealer immediately.
1. Remove the plastic blanking plug
from the air inlet connection.
2. Pour 2-3 drops of CLARKE airline oil
into the air inlet 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 connector 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 drill 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 A COMPRESSED AIR SUPPLY.

8
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INSERTING/REMOVING THE DRILL BIT
1. Open the chuck jaws by gripping
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
accept the drill bit.
4. Insert the drill bit in the jaws of the
chuck as far as it will go without
gripping the cutting part of the bit.
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.
Your drill is now ready for use.
OPERATION
SETTING THE SPEED
1. Set the tool speed by rotating the
control to one of the four settings.
• The numbers on the speed
control knob indicate the
speed setting when aligned
with the reference mark on the
air inlet. Speeds available are
(+/-10%):
111,000 rpm
215,000 rpm
318,000 rpm
420,000 rpm
Drill bit
Chuck jaws Close
Open
Chuck
key
jaws
jaws
Barrel

9
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
OPERATING THE DRILL
1. Slide the throttle locking lever
forward while squeezing the
trigger against the body of the
tool.
2. Do not use excess pressure on the
drill bit as this will shorten its life.
3. Release the trigger to stop the
drill.
• The drill will continue to rotate
briefly after the trigger has
been released.
4. Always ensure the drill has stopped before putting it down.
SETTING THE EXHAUST DEFLECTOR
The direction of the exhaust air
leaving the tool can be adjusted by
rotating the exhaust deflector.
Twist the 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.
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, replace the blanking plug to the air inlet once the airline
is disconnected.

10
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
MAINTENANCE
Please note that factors other than the drills condition 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.
DAILY
1. Before use, drain water from the air-line and compressor.
2. Lubricate the drill daily for optimum performance. Use CLARKE high quality
airline oil either via a lubricator in the air supply system or by placing a few
drops into the air inlet immediately before use. This should be carried out
regardless of whether or not an in-line lubricator is used.
CLEANING & OVERHAUL
1. Keep the drill clean and free from debris.
2. If the drill becomes sluggish and the air supply is of good quality, it may be
necessary to replace worn or damaged parts.
3. Grit or gum deposits in the
mechanism may eventually
reduce efficiency. This condition
can be corrected by cleaning the
air inlet filter and flushing out the
drill with gum solvent oil or an
equal mixture of SAE No10 oil and
paraffin.
4. Failing this, the drill should be
disassembled, thoroughly
cleaned, dried and reassembled.
You may prefer to take the drill to your CLARKE dealer if internal
maintenance is required.
WARNING: MAKE SURE THAT THE DRILL IS DISCONNECTED FROM THE AIR
SUPPLY BEFORE PERFORMING ANY CLEANING OR MAINTENANCE.

11
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
TROUBLESHOOTING
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 Air Line Oil (part no. 3050825) is available from your CLARKE dealer
along with a wide range of drill bits. The toughest and most durable of these
are the cobalt steel sets, ideal for stainless steel and hard alloys.
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 and clean 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. O-rings damaged or
ill-fitting in seat.
1. Return to CLARKE dealer
for repair.

12
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PARTS DIAGRAM

13
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PARTS LIST
No Description No Description
1 Main housing 21 O-ring
2 Housing liner 22 Screw
3 Bushing 23 Decorative ring
4O-ring 24Bearing
5 Trigger 25 Rear plate
6 Trigger lever 26 Steel ball
7 Spring 27 Rotor
8 Pin 28 Rotor blade
9 Trigger Pin 29 Cylinder
10 Air inlet 30 Bushing
11 Spring 31 Front plate
12 Pin 32 Steel ball
13 O-ring 33 Pin
14 Air regulator 34 Bearing
15 O-ring 35 Collet seat
16 Exhaust deflector 36 Lock ring
17 O-ring 37 Front protective cover
18 O-ring 38 Chuck
19 Valve stem 39 Screw
20 Spring 40 Chuck key

14
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY

15
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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.