Clarke CAT36B Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0315
STRAIGHT DIE GRINDER
MODEL NO: CAT36B, CAT89 & CAT98
PART NO: 3110436, 3110845 & 3110854

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INTRODUCTION
Thank you for purchasing this CLARKE Air Tool.
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.

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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 tool.
USE OF POWER TOOLS
1. Stay alert and use common sense - do not operate this tool when you are
tired or under the influence of alcohol, drugs or medication.
2. Always wear eye protectors when using air tools. 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 gasses, or any bottled gas, as a
source of power for this tool. This product should only be used with a
suitably rated compressed air supply.
6. Do not connect the air supply hose with your finger on the trigger.
7. Do not fit the tool to any stand or clamping device that may damage it.
8. Do not exceed the maximum pressure for the tool of 90 psi / 6.2 bar.
9. Keep the air supply hose away from heat, oil and sharp edges.
10. Check hoses for leaks or excessive wear before use, and ensure that all
connections are secure.
11. Do not use the tool for any other purpose than described in this manual.
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.
• The tool will be left unattended.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• Moving to another work area.
• Passing the tool to another person.
14. Never use the tool if it is defective or operating abnormally.
15. This tool should be serviced at regular intervals by qualified service
personnel.
16. Avoid damaging the tool for example by applying excessive force.
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.
USE OF THE GRINDING TOOLS
1. Ensure that sparks and particles resulting from use do not create a hazard,
Use screens where appropriate.
2. Never bump the grinding stones onto the workpiece, or let it hit any other
objects while grinding.
3. Always allow the tool to run up to full operating speed before applying it to
the job.
4. Use clamps, or vices to hold the workpiece. Failure to secure the workpiece
could result in personal injury.
TRANSPORTATION & STORAGE
1. Never carry an air tool by the air supply hose.
2. Never carry an air tool with your finger on the trigger.
3. When not in use, the tool must 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 in cold environments.

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OVERVIEW
The CAT89 Die Grinderis identical to the CAT98 other than in the body style.
The CAT36B Die Grinder KIt includes a CAT89 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 immediatey.
NO DESCRIPTION NO DESCRIPTION
1 Moulded Storage Case (CAT36) 4 Male Snap Connector
2 CAT89 Die Grinder 5 10 Grinding Stones (CAT36B only)
3 2 x Collet Wrenches 6 2 x Collets (1 already fitted to tool)

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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 & topped up with oil. Clarke air-line 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 A COMPRESSED AIR SUPPLY.

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. If required, connect an in-line mini oiler to the tool.
• A mini oiler helps to prolong the life of the air tool.
2. 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 inlet connector or via the hose
at the nearest connection to the air supply.
3. Connect a suitable hose as shown.
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.
• PTFE tape may be helpful for
sealing threaded connections.
6. 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).
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.
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.

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FITTING THE GRINDING STONE
IMPORTANT: Never use chipped or cracked grindstones.
1. Slip the shank of the chosen stone
into the collet and tighten the
screw cap finger tight.
2. Place one wrench over the collet
seat to stop the tool from rotating.
3. Use the other wrench to fully
tighten the collet and grip the
stone in position as shown.
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.
Always ensure the grinder has stopped before putting it down.
SETTING THE SPEED
1. Adjust the tool speed by setting
the air regulator on top of the tool
body using a suitable screwdriver.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released.

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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.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Motor parts worn.
2. Worn or sticking
mechanism due to
lack of lubricant.
1. Return to Clarke dealer
for repair.
2. 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. Air-line regulator in
closed position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
blockage. Drip a few
drops of air tool lubricat-
ing oil into air inlet.
2. Adjust in-line 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.