Clarke X-Pro CAT206 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 - ISS 1
¼”RIGHT ANGLE DIE GRINDER
MODEL NO: CAT206
PART NO: 3120523

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INTRODUCTION
Thank you for purchasing this CLARKE Die Grinder which is ideal for light tasks
such as automotive porting & polishing applications.
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 CAT206
Dimensions (L x W x H) 183 x 144 x 56 mm
Weight 0.52 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 20000 rpm @ 90psi
Speed Settings and rpm Setting 1 - 11,000 rpm
Setting 2 - 15,000 rpm
Setting 3 - 18,000 rpm
Setting 4 - 20,000 rpm
Sound Pressure Level (LpA dB) 88 dB(A)
Sound Power Level (LwA dB) 99 dB(A)
Vibration Levels 2.9 m/s2

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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 visitors away - Do not let children handle the
tool.
4. DO NOT operate the 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 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 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. ALWAYS 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. ALWAYS 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.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• The tool is not in use.
• The tool will be left unattended.
• Moving to another work area.
14. NEVER use the tool if it is defective or operating abnormally.
15. Avoid damaging the tool for example by applying excessive force.
16. ALWAYS maintain the tool with care. Keep it clean for the best and safest
performance.
17. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
18. DO NOT force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
19. 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.
20. NEVER carry the tool by the air supply hose.
21. NEVER carry the tool with your finger on the trigger.
22. When not in use disconnect the tool from the air supply and store in a dry
place out of the reach of children.

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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.

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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.
OVERVIEW
When opening the carton 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
1 Right Angle Drive 5 Air Exhaust Deflector
2 Trigger 6 Inlet Connector
3 Air Inlet 7 11mm Collet Wrench
4 Speed Control 8 17mm Collet Wrench

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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 CLARKE airline oil into the inlet 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 inlet 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
squeeze the trigger for approximately 30 seconds. The oil volume is
correctly 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.
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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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 may already
be installed in the grinder.
3. 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.
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 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 numbers on the speed
control knob indicate the
speed setting when aligned
with the reference mark on the
air inlet. Speeds available are
(+/-10%):
111,000 rpm
215,000 rpm
318,000 rpm
420,000 rpm

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OPERATING THE DIE GRINDER
1. 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
for a short time after the trigger has been released.
4. Always ensure the grinder has stopped before putting it down.
SETTING THE EXHAUST DEFLECTOR
The direction of the exhaust air
leaving the tool can be adjusted by
rotating the exhaust deflector.
Twist the exhaust deflector sleeve to
direct the air as required to deflect air
away from the workpiece or operator.
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.
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.

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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 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.

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MAINTENANCE
DAILY
1. Before use, drain water from the air tank, air line and compressor.
2. If no line lubricator or mini oiler is used, ensure that oil is applied to the 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 tool air inlet,
(ensuring the strainer is clear), or into the hose at the nearest connection to
the air supply. Then operate the tool.
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 the tool
may also 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 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 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.

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3. You may prefer to take the tool to your CLARKE dealer if internal
maintenance is required.
GREASING
The right angle drive is fitted with a
grease nipple to provide a facility for
lubrication of the drive gears.
1. After extensive use, apply a shot
of general purpose grease using a
suitable grease gun.
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 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.
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.

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DECLARATION OF CONFORMITY

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PARTS LIST
No Description No Description
1 Main Housing 25 Set pin
2 Housing liner 26 Rotor
3 Bushing 27 Rotor blade
4 O-ring 28 Cylinder
5 Trigger 29 Bushing
6 Lever 30 Front plate
7 Spring 31 Steel ball
8 Pin 32 Bearing
9Triggerpin 33Gear
10 Air inlet 34 Seal ring
11 Spring 35 Lock ring
12 Pin 36 Hex nut
13 O-ring 37 Right angle gear head
14 Air regulator 38 Grease cap
15 O-ring 39 Bearing
16 Exhaust deflector 40 Gear
17 O-ring 41 Bushing
18 O-ring 42 Work spindle
19 Valve stem 43 Woodruff key
20 Spring 44 Collet
21 O-ring 45 Collet jacket
22 Screw 46 Small Wrench
23 Bearing 47 Large Wrench
24 Rear plate

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COMPONENT PARTS DIAGRAM
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.