Clarke X-Pro CAT201 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1119 - ISS 1
DIE GRINDER KIT
MODEL NO: CAT201
PART NO: 3120518

2
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INTRODUCTION
Thank you for purchasing this CLARKE Die Grinder Kit.
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.
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.
Model Number CAT201
Dimensions (L x W x H) 169 x 37 x 66 mm
Weight 0.38 kg
Collet size 1/4”(6 mm)
Air Inlet Size 1/4”BSP (female)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4 cfm (average)
No Load Speed 25,000 rpm @ 90psi
Speed Settings and rpm Setting 1 - 8,300 rpm
Setting 2 - 13,000 rpm
Setting 3 - 22,000 rpm
Setting 4 - 25,000 rpm
Sound Pressure Level (LpA dB) 88 dB(A)
Sound Power Level (LwA dB) 99 dB(A)
Vibration Levels 2.9 m/s2

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 bystanders away - Do not let children handle air
tools.
4. DO NOT operate the air tool where there are flammable liquids or gases.
USE OF AIR POWERED TOOLS
1. ALWAYS 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 air tool - Eye protectors must
provide protection from flying particles from the front and the side.
3. ALWAYS wear ear protectors 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 air tool.
6. DO NOT connect the air supply hose with your finger on the trigger.
7. DO NOT exceed the maximum pressure for the air 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 air 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 air tool to a stand or clamping device that may damage it.
12. DO NOT carry out any alterations or modifications to the air tool.
13. ALWAYS disconnect from the air supply when:
• Performing any maintenance
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 air tool is not in use
• The air tool will be left unattended
• Moving to another work area
14. NEVER use the air tool if it is defective or operating abnormally.
15. ALWAYS avoid damaging the tool by applying excessive force.
16. ALWAYS maintain the air tool with care. Keep it clean 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 air tool. It will do a better and safer job at the
rate for which it was designed.
19. This air tool vibrates with use. Vibration may be harmful to your hands or
arms. Stop using the air tool if discomfort, a tingling feeling or pain occurs.
Seek medical advice before resuming use.
20. NEVER carry the air tool by the air supply hose.
21. NEVER carry the air tool with your finger on the trigger.
22. When not in use the air tool must be disconnected from the air supply and
stored in a dry place out of the reach of children.

5
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
OVERVIEW
When opening the blow moulded case for the first time, check that all the
items are present. Any damage or deficiency should be reported to your
CLARKE dealer immediately.
NO DESCRIPTION NO DESCRIPTION
A 2 x Collet wrenches (11mm &
17mm)
D Grinding stones (6mm shank)
B Spare collet E Grinding stones (3mm shank)
C 1/4” BSP Air hose connector
1 Trigger 4 Exhaust deflector
2 Air Inlet 5 Screw cap
3Speedcontrol

6
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 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.
.
Use only clean, dry, regulated compressed air as a power source.
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]
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 air tool.
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.
BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the plastic blanking plug from the air inlet connection.
2. Pour 2-3 drops of airline oil into the oil filling 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 snap 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 hold
the throttle open for approximately 30 seconds. The oil volume is correctly
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]
set when a light stain of oil can be seen on the paper. Excessive oil should
be avoided.
Your die grinder is now ready for use.
INSTALLING THE COLLET
1. Select the grinding stone you require.
2. 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.
3. If the other collet is to be used,
undo the screw cap completely
and pull out the collet from the
collet holder. Replace it with the
new collet and screw the cap loosely back on.
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 the smaller of the two
wrenches (11mm) over the collet
seat to stop the tool from rotating.
3. Use the larger wrench (17mm) to
fully tighten the collet and grip the
stone in position as shown.
4. If another 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.

9
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
ADJUSTING 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: 8300,
13000, 22000 or 25000 rpm (+/-
10%).
OPERATING THE DIE GRINDER
1. Slide the throttle locking lever
forward while squeezing the
trigger against the tool body.
2. Do not use pressure on the stone
as this will shorten its life.
3. Release the trigger to stop the
grinder.
• The tool will continue to rotate
for a short time after the trigger
has been released.
4. Always ensure the grinder has stopped before putting it down.
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.

10
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
TROUBLESHOOTING
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.
Avoid storing the tool where the temperature is below 0oC.
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 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. 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 reservoir, air line and compressor.
2. If no line lubricator or mini oiler is used, ensure that oil is applied to the air
tool on a daily basis through the air inlet connection. Run a few drops of oil
through the tool before use. It may be entered into the air tool air inlet,
(ensuring the strainer is clear), or into the hose at the nearest connection to
the air supply.
3. This procedure should be repeated after every two to three hours of use or
at the start of the working day.
4. Keep the body of the tool clean and free from debris.
WEEKLY
1. Check the air inlet screen filter for
blockage and clean if necessary.
CLEANING
1. Grit or gum deposits inside an air
tool may reduce its efficiency.
2. After extensive use, remove the
inlet screen filter and flush out the
mechanism with gum solvent oil or
an equal mixture of CLARKE air-
line oil and paraffin. Allow to dry before use.
SERVICE AND REPAIR
1. If the air 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.
2. If the air tool still runs erratically or becomes inefficient, and the air supply is
of good quality, it may be necessary to dismantle the air motor and
replace worn or damaged parts.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE.

12
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
3. You may prefer to take the air tool to your CLARKE dealer if internal
maintenance is required.
PERFORMANCE
Please note that outside factors may effect the operation and efficiency of
the air tool.
These include reduced compressor output, excessive drain on the airline,
moisture ingress, restrictions in the air-line such as the use of connectors of
incorrect size or poor condition which will reduce the air supply.
Your air tool has been designed to give long & trouble free service. If, however,
having followed the instructions in this booklet carefully, you encounter
problems, take the unit to your local CLARKE dealer.
ACCESSORIES
A wide range of accessories are 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.
CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
SUITABLE STONES INCLUDE:
CAT144 (10 piece grinding stone set) part no 3120158.

13
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY

14
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS

15
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS - STRAIGHT DIE GRINDER
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 its
intended purpose. 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.
No Description No Description
1 Main Housing 21 O-ring
2 Housing liner 22 Screw
3 Bushing 23 Bearing
4 O-ring 24 Rear plate
5Trigger 25Setpin
6 Lever 26 Rotor
7 Spring 27 Rotor blade
8 Roll pin 28 Cylinder
9 Trigger pin 29 Bushing
10 Air inlet 30 Front plate
11 Spring 31 Steel ball
12 Pin 32 Bearing
13 O-ring 33 Collet seat
14 Air regulator 34 Lock ring
15 O-ring 35 Decoration ring
16 Exhaust deflector 36 Front protective cover
17 O-ring 37 Collet
18 O-ring 38 Collet jacket
19 Valve stem 39 Small wrench (11mm)
20 Spring 40 Large wrench (17mm)