Clarke CAT52 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0414
4” ANGLE GRINDER
MODEL NO: CAT52
PART NO: 3110685

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INTRODUCTION
Thank you for purchasing this CLARKE Grinding 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.
Your tool 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.
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.
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 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.

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• 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.
USE OF GRINDING DISCS
1. Never use cracked or chipped grinding discs.
2. Never use non-reinforced grinding discs.
3. Never use the tool without disc guard in place.
4. Only use for grinding operations.
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 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 the tool in environments where the temperature is below 0oC.

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OVERVIEW
When opening the carton 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 Disc Retaining Washer 4 Air Inlet
2 Trigger 5 Wrench with pins
3 Side Handle 6 Wrench without pins

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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 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.

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the blanking plug from the air inlet 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.
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).
FITTING THE SIDE HANDLE
1. Screw the side handle to the main
body as shown.
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 DISC
1. Remove the flange nut.
2. Fit the grinding disc, ensuring the
hole in the disc sits snugly over the
shoulder on the arbor.
3. Refit the flange nut, finger tight.
• Ensure the shoulder on the
flange nut fits inside the hole on
the grinding disc.
4. Using the wrenches supplied, fit the
wrench (without pins) onto the
grinder arbor to prevent it from
turning.
5. Fit the other wrench (with pins) into
the two holes in the flange nut.
Hold both wrenches firmly and
tighten by turning the wrench with
pins in a clockwise direction.
6. Remove the wrenches before use.
REPLACEMENT DISCS
• Replacement cutting discs are available from your Clarke dealer.
(Part number 6470700).
WARNING: ENSURE THE AIRLINE IS DISCONNECTED FROM THE TOOL.
WARNING: WHEN FITTING DISCS, ALWAYS INSPECT FOR DAMAGE ETC,
NEVER USE GRINDING DISCS IF THEY ARE CHIPPED OR CRACKED.

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USING THE ANGLE GRINDER
1. Connect the airline and turn the
air supply on.
2. Hold firmly using both hands, right
hand on the motor body and your
left hand on the handle.
3. To switch on, push the throttle lock
forward, at the same time depress
the throttle.
• Allow the grinder to reach full
speed and stabilise before
continuing.
4. Gently offer grinding disc to work piece, DO NOT FORCE IT, allow the
grinder to do the work for which it was designed.
IMPORTANT: Always keep the disc guard square to work the face, also DO
NOT use side of disc for grinding, this could cause the disc to shatter
resulting in personal injury.
5. When finished grinding, with the motor still running take the disc away from
the work, release the throttle and wait for the grinder to stop before
carefully putting it down.
• The tool will continue to rotate for a short time after the trigger has
been released.
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.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
drill.
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. 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.

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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.
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 inside the air
inlet, 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.
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.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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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.
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 CAT52
Weight 3.1lbs (1.8 kg)
Disc Type 4” x 1/4” (type27 depressed centre)
Air Inlet Size 1/4“BSP (female)
Hose size 3/8” ID
Operating Pressure 90 psi (6.2 bar)
Air Consumption 6 cfm average
No Load Speed 11000 rpm @ 90psi
Sound Pressure Level (LpA dB) 90.4 dB(A)
Vibration Levels 0.514 m/s2

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PARTS LIST & DIAGRAM

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PARTS LIST & DIAGRAM
No Part No Description No Part No Description
1 AG-30001 Exhaust Deflector 34 AG-30034 Motor Housing
3 AG-30003 Inlet 36 AG-30036 Housing Shield
5 AG-30005 Motor Lock Nut 37 WW-0010 Wave Washer
6 AG-30006 Muffler Felt 38 BB-06252 Ball Bearing
7 AG-30007 Throttle Lever Pin 39 AG-30039 Bearing Spacer
8 DG-14012 Throttle Valve Hsg Plug 40 AG-30040 Hexagon Nut
9 ORP-0100 O-Ring 41 AG-30041 Bevel Gear
10 DG-14010 Ball Bearing 43 BB-62022 Ball Bearing
11 DG-14011 Throttle Valve Spring 44 AG-30044 Arbor
12 AG-30012 Throttle Plunger 45 AG-30045 Bearing Cap
14 AG-30014 Throttle Lever 46 AG-30046 Centre Guard
15 DG-14027 Throttle Lever Lock 47 SW2-050A Spring Washer
16 DG-14028 Spring (Lever Lock) 48 S4-5012A Button Head Screw
17 SP-25220 Spring Pin 52 AG-30052 Flange
18 AG-30018 Gasket 53 AG-30053 Flange Rubber Shield
20 BB-06062 Ball Bearing 54 AG-30054 Flange Nut
22 AG-30022 Rear End Plate 55 AG-30055 Handle Bracket
23 SP-25180 Spring Pin 56 AP-70047 Handle
24 AG-30024 Cylinder --- AG-30057 Wrench (not shown)
26 AG-30026 Vane --- AG-30058 Wrench (not shown)
27 AG-30027 Rotor 59 AG-40059 Grinding Wheel
28 AG-30028 Spacer 60 DG-14045 Plunge Cap
29 AG-30029 Front End Plate K01 AG-40K01 Throttle Lever Kit
30 BB-60002 Ball Bearing K02 AG-40K02 Throttle Valve Kit
32 AG-30032 Bevel Pinion K03 AG-40K03 Bevel Gear Kit
33 AG-30033 O-Ring

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DECLARATION OF CONFORMITY