Clarke CAT66 User manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC08/13
3” CUT-OFF TOOL
Model No: CAT66 & CAT99
Model Nos: 3110730 & 3110855

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INTRODUCTION
Thank you for purchasing this CLARKE Cut-off Tool.
Before attempting to operate the tool, it is essential that you read this manual
thoroughly and carefully follow all instructions given. In doing so you will
ensure the safety of yourself and that of others around you, and you can also
look forward to the product giving you long and satisfactory service.
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 effect your statutory rights.
ENVIRONMENTAL PROTECTION
Do not dispose of this product or any unwanted materials with general
household waste. All tools, accessories and packaging should be
sorted, taken to a recycling centre and disposed of in a manner
which is compatable with the environment.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
SAFETY PRECAUTIONS
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.
Make sure that any other persons in the work area are suitably dressed
and are wearing eye and ear protection.
4. Keep the work area well lit.
5. Although the cut off tool may be used outdoors, do not leave it exposed
to the elements. Avoid direct sunlight, direct heat, rain/moisture etc.
6. Keep the air supply hose away from sources of heat, oil and sharp edges.
7. Do not fit the tool to a stand or clamping device that may damage it.
GENERAL USE
1. Always stay alert and use common sense - do not use this product when
you are tired or under the influence of alcohol or medication.
2. Always wear eye protection when using the cut-off tool to provide
protection from flying particles from the front and the side.
3. Always wear ear protectors when using the cut-off tool .
4. Do not over-reach. Keep proper footing and balance at all times.
5. Never use 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: (90 psi / 6 bar).
8. Check air hoses for leaks or worn condition before use and ensure that all
connections are secure.
9. Do not use the tool for any purpose other than that described in these
instructions.
10. Never carry out any alterations or modifications to this product.
11. Always disconnect from the air supply when:
Performing any maintenance
The tool is not in use
The tool will be left unattended
Moving to another work area
12. Never force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
13. Never use this product if it is defective / operating abnormally.
14. Never carry the cut-off tool with your finger on the trigger.
15. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
16. Always check the cut-off tool for any damage or any condition that
could affect its operation. Any damaged part should be properly
repaired.
17. Never attempt any repairs yourself. If you have a problem with this
product contact your local CLARKE dealer.
18. This product vibrates during use. Vibration may be harmful to your hands
or arms. Stop using the cut-off tool if discomfort, a tingling feeling or pain
occurs and seek medical advice before resuming use.
CUT-OFF TOOL SAFETY INSTRUCTIONS
1. Always use the cut-off tool in the manner and for the functions described
in these instructions.
2. Always ensure the cut-off tool is not moving and disconnected from the
air supply when changing discs etc.
3. Due to the possible presence of dust, always wear suitable respiratory
protection.
4. Never carry the cut-off tool by the air supply hose.
5. Always disconnect from the air supply when changing discs or when the
tool is not required for immediate use in order to avoid accidental
starting.
6. Always store this product in a dry, secure place out of reach of children or
untrained users.
7. Use both hands where possible to control the cut-off tool .
8. Always ensure the cut-off tool has stopped before putting it down after
use.
9. Never use cracked or chipped cutting discs. Always inspect discs for
damage before operating.
10. Never use non-reinforced cutting discs. Only use 3”dia max cutting discs
rated to at least the max speed of the cut-off tool (i.e.21,000rpm)
11. Never use the cut off tool without disc guard in place.
12. Never use the side of the cutting disc for grinding.
13. Only use the cut-off tool for cutting operations.
Additionally, please keep these instructions in a safe place for future reference.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
AIR SUPPLY REQUIREMENTS
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.
• 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 in the air compressor will accelerate wear and
corrosion in the moving parts. 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), line pressure may
need to be increased.
• Never exceed the maximum operating pressure for the tool.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.
• A pressure of 90psi with a flow of 6 cfm is required. Too high an air pressure
will shorten the life of the tool due to excessive wear.
A typical airline layout is shown. If an automatic in-line filter/regulator/
lubricator unit is used it will keep the tool in good condition, but should be
regularly checked and topped up with oil.
IMPORTANT: If a filter/lubricator unit is not used, the air tool should be
lubricated with 2 to 6 drops of oil, at least once a day or after 2 hours work,
depending upon the working environment. The oil can be inserted through
the airline connection fitting.

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BEFORE USE
CONNECTING THE AIR SUPPLY
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF COM-
PRESSORS AND COMPRESSED AIR SUPPLIES.
Note: Ensure the compressor is turned off.
1. Remove the plastic blanking plug from the connection port of the tool as
shown.
2. Pour 2-3 drops of CLARKE airline oil into the air inlet. This should be done
regardless of whether or not a lubricated air supply is to be used.
3. Connect a suitable hose to the tool as shown.
4. Connect the other end of the hose to the compressor. (A whip hose with a
quick fit coupling is available from your CLARKE dealer).
5. Turn on the air supply and check for air leaks. Rectify any found before
proceeding. The tool is now ready for use.
OPERATION
CAUTION: ENSURE YOU READ, UNDERSTAND AND APPLY SAFETY IN-
STRUCTIONS BEFORE USE.
1. Push safety lever (mounted on the throttle lever) forward and depress
throttle lever.
•Allow tool to run up to full
speed for a couple of seconds
before offering disc to work
piece.
2. Apply a steady, even pressure.
Do not force the tool. Too much
pressure can cause disc to break
and may even cause injury.
NOTE: DO NOT allow tool to free run
for an extended period of
time as this will shorten its life.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
ADJUSTING THE SPEED
The speed of the cut-off tool can be
adjusted using the screw-in regulator
in the tool body. A suitable screw-
driver will be required.
Turn the regulator clockwise or anti-
clockwise to suit.
CHANGING THE CUTTING DISC
WARNING: ENSURE AIR IS TURNED OFF AND TOOL IS DISCONNECTED
FROM THE AIR SUPPLY BEFORE REPLACING DISC.
1. Ensure the disc being fitted has a
speed rating greater than 21,000
RPM.
2. Install disc using spanner and hex
key supplied. Ensure that the
spacer is in place.
IMPORTANT: The use of parts other
than CLARKE replacement parts may
result in safety hazards, decreased
tool performance and may invali-
date your warranty.
Replacement cutting discs are available from your Clarke dealer. Part no
3110731.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air pressure released.
2. Once the pressure has been released, disconnect the air supply hose from
the tool.
MAINTENANCE
DAILY
1. Before use, drain water from air reservoir, air line and compressor as
appropriate.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
2. If no line lubricator is used, ensure that oil is applied to the tool on a daily
basis through the air inlet connection.
3. For lubricating the air motor, an air line lubricator should be used,
containing Clarke Air Line Oil, adjusted to 2 drops per minute. If this is not
possible, run a few drops of oil through the tool. 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.
Clarke Airline Oil is available from your CLARKE dealer, Part No 3050825.
CLEANING
1. Keep the body of the tool clean and free from debris.
2. Grit or gum deposits in the tool may also reduce efficiency. This condition
can be corrected by cleaning the air strainer and flushing out the tool
with gum solvent oil, or failing this, the tool should be disassembled,
thoroughly cleaned, dried and reassembled.
3. After extensive use, remove the
inlet screen filter and flush out the
mechanism with gum solvent oil
or an equal mixture of SAE No10
oil and paraffin. Allow to dry
before use.
4. Clean the air inlet filter screen
inside the hose adaptor.
5. If the tool 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. You may prefer to take the tool to your CLARKE dealer if internal
maintenance is required.
Your Clarke cut-off 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.
SERVICE AND REPAIRS
1. Keep the tool clean at all times, and ensure that the bolts securing the
case remain tight.
• All bearings etc, in this machine are lubricated with sufficient high grade
lubricant for the machines lifetime under normal operating conditions,
therefore no further lubrication is required.
• Be aware that outside factors may effect operation and efficiency, These
may include reduced compressor output, excessive drain on the airline,
moisture in suspension or restrictions in the line, or the use of connectors of
improper size or poor condition which will reduce air supply.
Gauze Filter
(located here)

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
• Any major servicing and repairs should be carried out by your local
CLARKE dealer or a qualified service technician.
STORAGE
1. Store the tool safely in its box in a dry, secure environment.
2. If the tool is not to be used for longer than 24 hours, run a few drops of
CLARKE airline oil into the air inlet and run the tool for a few seconds to
ensure that the oil has been well distributed throughout the tool.
3. When storing, ensure the blanking plug is replaced on the airline
connector once the airline has been disconnected.
**Clarke Airline Oil is available from your CLARKE dealer: Part No 3050825
TROUBLESHOOTING
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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
ACCESSORIES
A wide range of airline accessories is available from your nearest CLARKE
dealer, for further information, contact your nearest dealer, or telephone
CLARKE International Sales department on 01992 565300.
Suitable air line accessories include air filter/regulators, lubricators, hoses,
snap couplings, clips, gauges, valves.
Packs of 5 replacement cutting discs are available from your CLARKE dealer:
Part No 3110731
TECHNICAL SPECIFICATION
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.
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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
VIBRATION EMISSIONS
MODEL Nos: CAT66 & CAT99
DESCRIPTION: 3” CUT-OFF TOOL
Declared vibration emission value in accordance with EN12096
Measured vibration emission value - a: <2.5m/s2
Uncertainty value - K: _______
Highest measured reading in a single plane 1.9m/s2
Values determined according to EN28622-2
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 transmit-
ted to the operator via the handle, or hand used to steady the tool. Vibration
from about 2 to 1500 herz is potentially damaging and is most hazardous in
the range from about 5 to 20 herz.
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 specification panel below.
HAND-ARM VIBRATION

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
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/s2
may 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
above as a reference.
Some tools with a high vibration value, such as impact wrenches, are gener-
ally 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.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
DECLARATION OF CONFORMITY

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
PARTS LIST
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1telloCdnE100296LK181gnisuoHrotoM810296LK1
2recapS200296LK191wercSevlaV910296LK1
3wercSlanogaxeH300296LK102gniR'O'020296
LK1
4yeKnellA400296LK112gniR'O'120296LK1
5tuN500296LK122rotalugeRriA220296LK1
6reniateR600296LK132gnirpS320296LK1
7rennapS700296L
K142gniR'O'420296LK1
8a/N52elttorhT520296LK1
9gniraeBllaB900296LK162evlaV620296LK1
01etalPdnEtnorF010296LK172reveLelttorhT72029
6LK1
11niP110296LK382niPreveLelttorhT820296LK1
21rednilyC210296LK192rotcelfeDtsuahxE920296LK1
31recapSgniraeB310296LK103gniR
'O'030296LK1
41rotoR410296LK113a/n
51edalBrotoR510296LK423gnihsuBtelnI230296LK1
61etalPraeR610296LK133rotcetorPcitsalP330296
LK1
71gniraeBllaB710296LK143csiDgnittuC430296LK1
The above parts list apply equally to the CAT66 and CAT99. The only differ-
ence is that the external parts of the CAT99 are highly pollished and include
rubber grips. Should these parts be required, please contact your nearest
Clarke dealer, while referring to the parts list above.

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Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
PARTS DIAGRAM