Clarke CAT 89 Troubleshooting guide

OPERATION & MAINTENANCE
INSTRUCTIONS
0902
DIE GRINDER
MODEL NO: CAT 89
PART No: 3110845
DIE GRINDER

CONTENTS
Specifications .......................................................................... 4
Guarantee ............................................................................... 5
Safety Precautions .................................................................. 6
Operating Instructions ........................................................... 7
Maintenance .......................................................................... 7
Parts List & Diagram ............................................................... 8
Vibration Emmisions ...................... refer to notes on page 9
Blank Page ............................................................................ 10
Declaration of Conformity ................................................. 11
MODEL No: CAT89
DESCRIPTION: DIE GRINDER
Declared vibration emmission value in accordance
with EN ISO 8662-13
Measured vibration emmission value - a: <2.5m/s2
Uncertainty value - K: m/s2
Highest measured reading in a single plane 2.08m/s2
Values determined according to EN28622-1

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 machines data plate
Fig.1
SPECIFICATIONS
Model : .......................................................................... CAT 89
Part No : ....................................................................... 3110845
Free Speed ........................................................... 20,000 RPM
Collet Capacity ..................................................... 1/8” - 1/4”
Maximum Air Consumption :....................................... 8 CFM
Maximum Air Pressure : .................................. 90 PSI (6.2bar)
Air Inlet Size : ............................................................... 1/4” BSP
Minimum Hose Size : ..................................... 5/16” (8mm) ID
Weight : ........................................................................... 0.5 kg
Overall Length ............................................................... 5-1/2”

CLARKE 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 affect your statutory rights.
Please read these instructions carefully before operating the tool
Thank you for purchasing this CLARKE Air Die Grinder
Before using the device, please read this manual thoroughly and carefully follow
all instructions given. This is for your own safety and that of others around you, and
is also to helpyou achieve long and trouble free service from your new tool.
ACCESSORIES
A wide range of Airline accessories is available, including Filter/Regulators, Lubricators, High
Pressure Hoses from 5 to 100 Metres, etc. Contact your CLARKE dealer for further information,
or CLARKE International Sales Department on 01992 565300
PARTS & SERVICE TEL: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]

SAFETY PRECAUTIONS
IMPORTANT
Failure to follow these precautions could
result in personal injury, and/or damage to
property.
❐When operating this tool, ALWAYS wear:
a. approved impact resistant SAFETY
GOGGLES. (Eye glasses are NOT
safety glasses)
b. a DUST MASK
c. EAR DEFENDERS
d. a good pair of INDUSTRIAL GLOVES
❐ALWAYS disconnect the tool when not
in use, and before carrying out any
maintenance
❐ALWAYS keep a safe distance between
yourself and other people when using
the tool.
❐ALWAYS maintain the tool with care.Keep
it clean for best and safest performance.
❐NEVER wear ill fitting clothing, remove
watches and rings.
❐Quick change couplings should not be
located at the tool. They add weight
and could fail due to vibration.
❐DO NOT over-reach. Keep your proper
footing and balance at all times.
❐DO NOT force or misuse the tool. It will
do a better and safer job at the rate for
which it was designed.
❐DO NOT abuse hoses or connectors.
NEVER carry a tool by the hose, or yank
it to disconnect from the air supply. Keep
hoses away from heat, oil and sharp
edges. Check hoses for leaks or worn
condition before use, and ensure that
all connections are secure.
❐DO NOT exceed 90 PSI at the tool.
❐DO NOT modify the tool in any way.
❐DO NOT remove any labels. Damaged
labels should be replaced.
❐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.
❐ALWAYS use screens to protect people
in the vicinity from flying debris.
❐NEVER point the tool at anyone.
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 SUPPLY
Tools of this type, operate on a wide range
of air pressures. It is recommended that air
pressure to this tool does not exceed 90 PSI
(6.1bar), at the tool when running. Higher
pressure and unclean air, will shorten the tools’
life because of faster wear, and could be a
safety hazard.
Water in the air line will cause damage to
the tool, ensure it is properly maintained at
all times.
The recommended procedure to connect
this tool to an air supply, is shown at fig. 1 on
inside front cover.
The air inlet used for connecting air supply,
has a standard ¼” BSP thread.
Line pressure, or hose inside diameter, should
be increased to compensate for unusually
long air hoses (over 10m). Minimum hose
diameter should be 6mm (¼") ID., and fittings
should have the same inside dimensions.
ASSEMBLY
Connect a suitable hose to the Grinder using
a ¼” hose adapter, (A whip hose with Quick
Fit coupling is available from your CLARKE
dealer). then connect the other end to the
airline.
NOTE: ensure the airline is turned off.
Your Grinder is now ready for use.

Before starting work drain any water from
the air tank and blow condensation from
the air line. Drain compressor more frequently
in hot humid weather.
1. Ensure Grinder is disconnected from the
air supply.
2. Loosen collet nut, and insert appropriate
grinding stone. Tighten collet using
spanners supplied.
3. Depress throttle lever and wait until motor
is running at full speed.
4. Cautiously offer stone to workpiece,
DO NOT APPLY EXCESS FORCE, allow tool
to do the job for which it was designed,
too much pressure could cause stone to
shatter resulting in personal injury.
5. When finished grinding, allow grinder to
stop running before carefully putting it
down.
NOTE:
Grinding stones come with two different size
shafts 1/8” and 1/4”, therefore you will need
to fit different collets, Your grinder comes with
the 1/4” collet fitted.
If you need to fit the 1/8” collet, follow
instructions below.
a: hold motor spindle from turning (Item
7) with spanner supplied.
b: remove collet nut and withdraw
collet, store for re-use.
c: install new collet and re-fit collet nut,
(finger-tight only).
IMPORTANT
Never use chipped or cracked stones,
always inspect before fitting.
OPERATING INSTRUCTIONS
MAINTENANCE
IMPORTANT:
The use of parts other than CLARKE re-
placement parts may result in safety haz-
ards, decreased tool performance and
may invalidate your warranty.
Daily before use.
1. Drain water from air tank, air line and
compressor.
2. Check and clean, if necessary, the
air inlet gauze filter .
3. Pour a few drops of CLARKE Air Line
Oil (approx 3cc), into the air inlet. This
should be carried out regardless of
whether or not an air line lubricator
is used.
If an Air line lubricator is NOT used,
this procedure should be repeated
after every two to three hours of use.
If the grinder 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.
For lubricating the air motor when in
operation, an air line lubricator should be
used, with Clarke Air Line Oil, adjusted to 2
drops per minute.
Clarke Air Line Oil is available from your
CLARKE dealer, part no. 3050825.
Be aware 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
line, or the use of connectors of improper size
or poor condition which will reduce air supply.
Grit or gum deposits in the tool may also
reduce efficiency. This condition can be
corrected by cleaning the air strainer and tool
with air line oil, or failing this, the tool should
be disassembled, thoroughly cleaned, dried
and reassembled.
If the tool runs erratically or becomes
inefficient, and the air supply is sound,
dismantle the air motor and replace worn or
damaged parts, or take the tool to your
CLARKE dealer.

PARTS DIAGRAM
PARTS & SERVICE TEL: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]

PARTS LIST
Index No Part No Description Qty
I KL89001 Double Ended Spanner 1
2 KL89002 Double Ended Spanner 1
3 KL89003 Collet Nut 1
4 KL89004 Collet 1
5 KL89005 Housing Cap 1
6 KL89006 Retainer 1
7 KL89007 Spindle 1
9 KL89009 Ball Bearing 1
10 KL89010 Front End Plate 1
11 KL89011 Ball 3
12 KL89012 Cylinder 1
13 KL89013 ‘O’ Ring 1
14 KL89014 Rotor 1
15 KL89015 Rotor Blade 4
16 KL89016 Rear Plate 1
17 KL89017 Ball Bearing 1
18 KL89018 Motor Housing 1
19 KL89019 Valve Screw 1
20 KL89020 ‘O’ Ring 1
21 KL89021 ‘O’ Ring 1
22 KL89022 Air Regulator 1
23 KL89023 Spring 1
24 KL89024 ‘O’ Ring 1
25 KL89025 Throttle Valve 1
27 KL89027 Throttle Lever 1
28 KL89028 Throttle Lever Pin 1
29 KL89029 Exhaust deflector 1
30 KL89030 ‘O’ Ring 1
31 KL89031 Circlip 1

Employers are advised to refer to the HSE publication “Guide for Employers”.
All hand held power tools vibrate to some extent, and this vibration is transmitted to the operator
via the handle, or hand used to steady the tool. Vibration from about 2 to 1500 hertz is potentially
damaging and is most hazardous in the range from about 5 to 20 hertz.
Operators who are regularly exposed to vibration may suffer from Hand Arm Vibration Syndrome
(HAVS), which includes ‘dead hand’, ‘dead finger’, and ‘white finger’. These are painful
conditions and are widespread in industries where vibrating tools are used.
The health risk depends upon the vibration level and the length of time of exposure to it……in
effect, a daily vibration dose.
Tools are tested using specialised equipment, to approximate the vibration level generated under
normal, acceptable operating conditions for the tool in question. For example, a grinder used at
45° on mild steel plate, or a sander on softwood in a horizontal plane etc.
These tests produce a value ‘a’, expressed in metres per second per second, which represents the
average vibration level of all tests taken, in three axes where necessary, and a second figure ‘K’,
which represents the uncertainty factor, i.e. a value in excess of ‘a’, to which the tool could
vibrate under normal conditions. These values appear in the declaration on page 7.
HAND-ARM VIBRATION
You will note that a third value is given in the specification - the highest measured reading in a
single plane. This is the maximum level of vibration measured during testing in one of the axes,
and this should also be taken into account when making a risk assessment.
‘a’ values in excess of 2.5 m/s2are considered hazardous when used for prolonged periods. A
tool with a vibration value of 2.8 m/s2may be used for up to 8 hours (cumulative) per day,
whereas a tool with a value of 11.2 m/s2may be used for ½ hour per day only.
The graph below shows the vibration value against the maximum time the respective tool may
be used, per day.
The uncertainty factor should also be
taken into account when assessing a
risk. The two figures ‘a’ and ‘K’may
be added together and the resultant
value used to assess the risk.
It should be noted that if a tool is used
under abnormal, or unusual
conditions, then the vibration level
could possibly increase significantly.
Users must always take this into
account and make their own risk
assessment, using the graph as a
reference.
Some tools with a high vibration value, such as impact wrenches, are generally used for a few
seconds at a time, therefore the cumulative time may only be in the order of a few minutes per
day. Nevertheless, the cumulative effect, particularly when added to that of other hand held
power tools that may be used, must always be taken into account when the total daily dose rate
is determined.