Clarke air CAT129 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0522 - rev 2
AIR DIE GRINDER/KIT
MODEL NO: CAT128/CAT129
PART NO: 3120142/ 3120143

2
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INTRODUCTION
Thank you for purchasing this CLARKE Die Grinder/Kit which is ideal for light
tasks such as porting & polishing of automotive components.
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.
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.
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. The following safety symbols are to be found on the machine.
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.
Read this instruction
booklet carefully
before use.
Wear ear protection.
Wear eye protection. Wear dust mask.

3
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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.
USE OF POWER 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 and a dust mask 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. 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. 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.

4
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
• The tool will be left unattended.
• Moving to another work area.
• Passing the tool to another person.
14. Never use the tool if it is defective or operating abnormally.
15. The tool should be serviced at regular intervals by qualified service
personnel.
16. Avoid damaging the tool for example by applying excessive force of any
kind.
17. Always maintain the tool with care. Keep it clean for the best and safest
performance.
18. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
19. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
20. Do not remove any labels. Damaged labels should be replaced.
21. 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 AND STORAGE
1. Never carry the tool by the air supply hose.
2. Never carry the tool with your finger on the trigger.
3. When not in use the tool should be disconnected from the air supply and
stored in a dry place out of the reach of children (preferably in a locked
cabinet).
4. Avoid storing the tool in environments where the temperature is below 0oC.

5
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
OVERVIEW
The CAT128 Die Grinder is available as an individual item or as part of the
CAT129 Die Grinding Kit.
The CAT129 Die Grinder KIt includes a CAT128 Die Grinder together with the
accessories shown. When opening the case for the first time, check against
the following list that all the items are present. Any damage or deficiency
should be reported to your CLARKE dealer immediately.
NO DESCRIPTION NO DESCRIPTION
1 Moulded Storage Case
(CAT129 only)
4 Male Snap Connector
2 CAT128 Die Grinder 5 10 Grinding Stones (CAT129 only)
3 2 x Collet Wrenches 6 3 x Collets (1 already fitted to tool)

6
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPRESSED AIR REQUIREMENTS
• 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.
• 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.
• 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.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLY.

7
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the blanking plug from the inlet connection of the tool.
2. If required, connect an in-line mini oiler to the tool.
• A mini oiler helps to prolong the life of the air tool.
3. 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 air inlet or via the hose
at the nearest connection to the
air supply.
4. Connect a suitable hose to the air
inlet as shown.
5. Connect the other end of the hose
to the compressor.
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.

8
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INSTALLING THE COLLET
1. Select the grinding stone you require.
2. Three 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.
3. If a different 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.
FITTING THE GRINDING STONE
IMPORTANT: Never use chipped or cracked grindstones. Never use
grindstones not rated to operate at a speed equal to, or greater than, the
full operating speed of the air tool.
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 tool from rotating.
3. Use the larger wrench to fully
tighten the collet and grip the
stone in position as shown.
ADJUSTING 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: 8300,
13000, 22000 or 25000 rpm (+/-
10%).

9
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
OPERATING THE DIE GRINDER
1. Use your thumb to slide the
throttle locking lever forward while
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.
• The tool will continue to rotate
very briefly after the trigger has been released.
4. Always ensure the grinder has stopped before putting it down.
SETTING THE EXHAUST AIR DEFLECTOR
The direction of the exhaust air
leaving the tool can be adjusted by
rotating the exhaust air deflector.
Twist the exhaust air deflector sleeve
to direct the air as required away from
the workpiece or operator.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released.
2. Refer to the compressor instruction manual for the procedure to shut down
and release the compressed air.
3. Once the pressure has been released, disconnect the air supply hose from
the tool.
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, ensure the blanking plug is replaced on the airline
connector once the airline is disconnected.

10
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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.
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. 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.

11
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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.
WEEKLY
1. Check the air inlet strainer for
blockage and clean if necessary.
CLEANING
1. Keep the body of the tool clean
and free from debris.
2. 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. 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 STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

12
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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.
SPECIFICATIONS
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 CAT128
Tool Dimensions (L x W x H) 172 x 46 x 68
Tool Weight 0.4 kg
Air Inlet Size 1/4“BSP (female)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4 cfm average/ 16 cfm at max load
No Load Speed 25000 rpm @ 90psi
Sound Pressure Level (LpA dB) 88 dB(A)
Sound Power Level (LwA dB) 99 dB(A)
Vibration Levels 2.9 m/s2

13
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PARTS LIST & DIAGRAM

14
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PARTS LIST & DIAGRAM
No Description No Description
1 Main Housing 23 Air Inlet
2 Trigger 24 Housing Cover
3 Locking Lever 25 Gasket
4 Spring 26 Rear Rotor Bearing
5 Pin 27 Rear Plate
6TriggerPin 28Pin
7 Soft Grip 29 Rotor
8 O-Ring 30 Rotor Blade
9 O-Ring 31 Cylinder
10 Valve Stem 32 Rotor Collar
11 Valve Spring 33 Front Plate
12 O-Ring 34 Pin
13 Valve Plug 35 Front Rotor Bearing
14 Valve Bushing 36 Valve Bushing
15 O-Ring 37 Clamp Nut
16 Exhaust Deflector 38 Protector
17 O-Ring 39 Collet Holder
18 Air Regulator 40 Collet
19 Set Plate 41 Screw Cap
20 O-Ring 42 Small Wrench
21 Set Plate 43 Large Wrench
22 Gasket

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