Clarke CAT127 Cut-Off Tool Instruction Manual

Cut-Off Tool
Instruction Manual 

CUT-OFF TOOL
MODEL NO: CAT127
PART NO: 3120141
OPERATING & MAINTENANCE INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0522 – rev 3

INTRODUCTION

Thank you for purchasing this CLARKE Cut-Off 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.

IMPORTANT
Please read all of the safety and operating instructions carefully before using this product. The following safety symbols are to be found on the machine.

| Read this instruction booklet carefully before use.| | Wear ear protection.
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| Wear eye protection.| | Wear dust mask.

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 affect your statutory rights.

GENERAL SAFETY RULES

CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.
WORK ENVIRONMENT

1. Keep the work area clean and tidy.
2. Dress appropriately – Do not wear loose clothing or jewelry. Tie long 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, CO 2 , 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 conditions 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.
    • 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 an 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 at 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 CUTTING DISCS

1. Never use cracked or chipped cutting discs.
2. Never use non-reinforced cutting discs.
3. Never use the cut-off tool without a disc guard in place.
4. Never use the side of the cutting disc for grinding.
5. Only use for cutting 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 0 C.

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.

COMPRESSED AIR REQUIREMENTS

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF COMPRESSORS AND COMPRESSED AIR SUPPLY.

• Use only clean, dry, regulated compressed air as a power sourc

• 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 airline 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.

BEFORE 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.
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).

INSTALLING THE CUTTING DISC

1. Ensure the disc being fitted has a speed rating greater than 20,000 rpm which is the maximum speed of the tool.
2. Install the disc and retaining washer using the spanner and hex key supplied.
   NOTE: The disc must be fitted with the metal facing touching the retaining washer.
   IMPORTANT: The use of parts other than CLARKE replacement parts may result in safety hazards, decreased tool performance and may invalidate your warranty.
   • Replacement cutting discs are available from your Clarke dealer. (Part number 3120159).

ADJUSTING THE SPEED

1. Set the tool speed by rotating the control to one of the four settings.
   • The graduations on the speed control indicate the speed setting when aligned with the reference mark on the air inlet.
   • Speeds available are: 4880, 6800, 15400 or 20000 rpm (+/10%).

OPERATING THE TOOL

1. Use your thumb to slide the throttle locking lever forward at the same time as squeezing the trigger against the body of the tool.
   • Allow the tool to run up to full speed for a couple of seconds before offering the disc to the workpiece.

2. Apply a steady, even pressure. Do not force the tool.

3. Too much pressure can cause the disc to break and may shorten the life of the tool.

4. Release the trigger to stop the tool.
   • The tool will continue to rotate for a short time after the trigger has been released.

5. Always ensure the tool has stopped before putting it down.

SETTING THE AIR EXHAUST DEFLECTOR
The direction of the exhaust air leaving the tool can be adjusted by rotating the air exhaust deflector. Twist the air 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 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.

TROUBLESHOOTING

pressure on the tool.
2. Motor parts are 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 the air inlet. Allow the oil to soak moving parts before using.
The tool runs slowly. Air flows weakly from the exhaust.| 1. Motor parts jammed with gum/dirt.
2. Regulator in the closed position.
3. General airflow blocked by dirt.| 1. Examine the inlet air filter for cleanliness.
2. Adjust the regulator to an open position.
3. Operate tool in short bursts.
The tool will not run. Air flows freely from the exhaust.| 1. Motor vanes stuck due to buildup of foreign material.| 1. Disconnect air supply and rotate tool assembly manually.
2. Try operating the tool in
short bursts.
3. Tap the motor housing gently with a rubber mallet.
4. Drip a few drops of air tool lubricating oil into the air inlet to soak moving parts.
The tool will not shut off.| 1. Throffle 0-rings damaged or ill-filling in the seat.| 1. Return to Clarke dealer for repair.

MAINTENANCE

WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE PROCEDURES.
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 inline mini oiler is not used, this procedure should be repeated after every two to three hours of use.

WEEKLY

1. Check the air inlet screen filter for blockage and clean if necessary.
   

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 affect 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.
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 meters) 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 reserves the right to change specifications at any time without prior notice. Always consult the machine’s data plate.

PARTS LIST & DIAGRAM

PARTS LIST & DIAGRAM 

DECLARATION OF CONFORMITY

A SELECTION FROM THE VAST RANGE OF

| QUALITY PRODUCTS
AIR COMPRESSORS
From DIY to industrial, Plus air tools, spray guns, and accessories.
GENERATORS
Prime duty or emergency standby for business, home and leisure.
POWER WASHERS
Hot and cold, electric and engine driven • we have what you need
WELDERS
Mig, Arc, Tig, and Spot. From DIY to auto/industrial.
METALWORKING
Drills, grinders, and saws for DIY and professional use.
WOODWORKING
Saws, sanders, lathes, mortises, and dust extraction.
HYDRAULICS
Cranes, body repair kits, and transmission jacks for all types of workshop use.
WATER PUMPS
Submersible, electric, and engine drove for DIY, agriculture and industry.
POWER TOOLS
Angle grinders, cordless drill sets, saws, and sanders.
STARTERS/CHARGERS
All sizes for car and commercial use.|
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PARTS & SERVICE:
0208 988 7400
Parts Enquiries Parts@clarkeinternational.com
Servicing & Technical Enquiries Service@clarkeinternational.com
SALES: UK 01992 565333 or Export 00 44 (0)1992 565335
INTERNATIONAL Heilman Street, Epping, Essex CM16 4LG
www.clarkeinternational.com

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