Clarke Air CAT112 Installation and operation manual

14 PIECE DIE GRINDER KIT
Part No: 3120132
MODEL No: CAT112
OPERATING & MAINTENANCE
INSTRUCTIONS
GC0409

2
INTRODUCTION
Thank you for purchasing this CLARKE product.
Before attempting to use the tool, 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 the tool
giving you long and satisfactory service.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt 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
Do not dispose of this product with general household waste. All tools,
accessories and packaging should be sorted, taken to a recycling
centre and disposed of appropriately.
PARTS & SERVICING
For parts & Servicing, please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]

3
CONTENTS
Introduction ............................................................................................ 2
Guarantee .............................................................................................. 2
Environmental Protection ...................................................................... 2
Parts & Service Contacts ....................................................................... 2
Table of Contents ................................................................................... 3
Technical Specification ......................................................................... 3
Overview ................................................................................................ 4
General Safety Precautions .................................................................. 5
Air Supply Requirements ....................................................................... 7
Assembly & Operation .......................................................................... 8
Troubleshooting .................................................................................... 10
Maintenance ........................................................................................ 11
Parts Lists and Diagrams ..................................................................... 12
Vibration Emissions .............................................................................. 13
Declaration of Conformity .................................................................. 15
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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.
TECHNICAL SPECIFICATION

4
OVERVIEW
The CAT112 Die Grinder is ideal for light tasks such as automotive porting &
polishing applications. The lightweight composite housing also helps to
reduce vibration & a lever lock throttle is provided for extra safety.
Unpack and lay out the components, checking against the following list. Any
damage or deficiency should be reported to your CLARKE dealer
immediately.
1. Die Grinder
2. Moulded Storage Case
3. Male Snap Connector
4. 2 x Collets
5. 2 x Collet Wrenches
6. 10 Grinding Stones
7. Operators Manual (this document)
Your Die Grinder 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.
1 2 3 6 4 5

5
GENERAL SAFETY PRECAUTIONS
WORK ENVIRONMENT
• Keep the work area clean and tidy.
• Dress appropriately - Do not wear loose clothing or jewellery. Tie long hair
out of the way.
• Keep children and visitors away - Do not let children handle the die
grinder. Make sure that any other persons in the work area are dressed
suitably and are wearing eye and ear protectors.
• Do not operate the die grinder where there are flammable liquids or
gases.
• Keep the air supply hose away from heat, oil and sharp edges.
• Do not fit the die grinder to any stand or clamping device that may
damage the tool.
GENERAL USE
• Stay alert and use common sense - do not operate the die grinder when
you are tired or under the influence of alcohol, drugs or medication.
• Always wear eye protection when using the die grinder - eye protection
must provide protection from flying particles from the front and the side.
• When grinding, always wear an appropriate face mask or respiratory
equipment to prevent inhalation of airborne dust.
• Always wear ear protectors when using the die grinder.
• Do not over-reach - Keep proper footing and balance at all times.
• Never use any type of bottled gas as a source of power for the die
grinder.
• Do not connect the air supply hose with your finger on the trigger of the
die grinder.
• Do not exceed the maximum pressure for the die grinder: 90 psi / 6.2 bar.
• Check hoses for leaks or worn condition before use and ensure that all
connections are secure.
• Do not use the die grinder for any other purpose than that described in
this booklet.
• Do not carry out any alterations or modifications to the die grinder.
• The die grinder should be serviced as required by your CLARKE dealer.
• Never use the grinder if it is defective or operating abnormally.

6
• Always disconnect from the air supply when:
a) Performing any maintenance.
b) The grinder is not in use.
c) The grinder will be left unattended.
d) Moving to another work area.
• Avoid damaging the die grinder for example by applying excessive force.
• ALWAYS maintain the tool with care. Keep it clean for best and safest
performance.
• Quick change air-line couplings should not be located at the tool. They
add weight and could fail due to vibration.
• DO NOT force or misuse the tool. It will do a better and safer job at the
rate for which it was designed.
• This tool vibrates during use. Vibration may be harmful to your hands or
arms. Stop using the tool if discomfort, a tingling feeling or pain occurs and
seek medical advice before resuming use.
• ALWAYS use only the grinding tools supplied with the machine. Non-
standard attachments could become detached during use with serious
consequences.
• ALWAYS ensure that any attachments are correctly fastened before
connecting the tool to the power supply.
• ALWAYS ensure the workpiece is firmly secured leaving both hands free to
control the tool.
• ALWAYS ensure the tool has stopped before putting it down after use.
TRANSPORTATION
• Never carry the die grinder by the air supply hose.
• Never carry the die grinder with your finger on the trigger.
STORAGE
• When not in use the die grinder must be disconnected from the air supply
and stored in a dry place out of the reach of children (preferably in a
locked cabinet).
• Avoid storing the die grinder in environments where the temperature is
below 0oC.

7
AIR SUPPLY REQUIREMENTS
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE THOROUGHLY FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE
USE OF COMPRESSORS AND COMPRESSED AIR SUPPLY.
• Air compressors used with the grinder must comply with the appropriate
European Community safety directives.
• Use only clean, dry, regulated compressed air.
• A build up of moisture in the air compressor will accelerate wear and
corrosion in the grinder. 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.
A typical airline
arrangement is shown
on the right. 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.
IMPORTANT: If a filter/lubricator unit is not used, the grinder 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 grinder. A pressure
of 90psi with a flow of 4 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.
• Ensure the trigger is OFF before connection the tool to the air supply.

8
ASSEMBLY & OPERATION
CONNECTION TO THE AIRLINE
1. Remove the plastic blanking plug
from the connection port of the die
grinder as in Fig 1.
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.
NOTE: Ensure the airline is turned OFF.
3. Connect a suitable hose to the die
grinder as shown. Use the screw-in
adapter supplied if required.
4. Connect the other end of the hose to
the compressor.
(A whip hose with a quick fit coupling is available from your CLARKE dealer).
5. Turn on the air supply and check for air leaks. Rectify any found before
proceding.
Your die grinder is now ready for use.
INSTALLING THE COLLET
1 Select the grinding stone you
require.
Two 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)
2. If the other 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 as in Fig 2.
FIG 1
FIG 2

9
OPERATING THE DIE GRINDER
1. Use your thumb to slide the
throttle lock forward at the
same time as 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.
4. Always ensure the grinder has
stopped before putting it down.
FITTING THE GRINDING STONE
IMPORTANT: Never use chipped or
cracked grind stones.
1. Slip the shank of the chosen
stone into the collet and
tighten the screw cap finger
tight.
2. Place the smaller of the two
wrenches over the collet seat
to stop the grinder from
rotating.
3. Use the larger wrench to fully
tighten the collet and grip the
stone in position as in Fig 3.
ADJUSTING THE SPEED
1. Regulate the flow of air as
required by adjusting the air
regulator on the body of the
die grinder.
2. To adjust the speed, turn the
air regulator as required using
a screwdriver as in Fig 4. Air Regulator
FIG 3
FIG 4
FIG 5

10
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released from the air line.
2. Once the pressure has been released, disconnect the air line from the die
grinder.
STORAGE
1. Store the die grinder safely in its box in a dry, secure environment.
2. If the grinder 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 die grinder.
3. When storing, ensure the blanking plug is replaced on the airline
connector once the airline is disconnected.
TROUBLESHOOTING
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In the event that any of the above situations occurs that requires dismantling
and overhaul of the tool, contact your CLARKE International Service
Department on 020-8988-7400.