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Clarke X-Pro CAT202 Operating & Maintenance Instructions

44-pc air tool kit
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44-PC AIR TOOL KIT
MODEL NO: CAT202
PART NO: 3120519
OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS
GC1219 ISS 1

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  • Page 1 44-PC AIR TOOL KIT MODEL NO: CAT202 PART NO: 3120519 OPERATING & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC1219 ISS 1...

  • Page 2: Air Tools

    Please keep these instructions in a safe place for future reference. INVENTORY When opening the case for the first time, check that all the items are present. Any damage or deficiency should be reported to your CLARKE dealer immediately. Your CAT202 air tool kit should include the following: AIR TOOLS 1 x ½”...

  • Page 3: Product Specifications

    FOR THE IMPACT WRENCH: • 6 x Impact Sockets, ½” Square Drive Sizes: 9 mm, 11 mm, 14 mm, 17 mm, 22 mm, & 24 mm • 1/2” Extension bar FOR THE DIE GRINDER: • 5 x Assorted Stones, • 2 x wrenches 6mm (1/4”) shank (11 and 17mm) •...
  • Page 4 Sound Pressure Level (LpA dB) 87 dB(A) Sound Power Level (LwA dB) 98 dB(A) Vibration Levels 4.35 m/s (uncertainty factor K= 1.5m/s Weight 2.49 kg Wrench Dimensions (L x W x H) 197 x 190 x 68 mm DIE GRINDER Dimensions (L x W x H) 169 x 37 x 66 mm Weight...
  • Page 5 AIR HAMMER/CHISEL Maximum Operating Pressure 90 psi (6.2 bar) Air Consumption (under load) 5 cfm Max Blows per Min. 4500 Variable speed Trigger operated Air Inlet Size 1/4” BSP female thread Vibration Levels 10.6 m/s (uncertainty factor K= 1.5m/s Sound pressure level 98 dB LpA Sound power level 111 dB LWA...

  • Page 6: General Safety Warnings

    RATCHET WRENCH Min. Hose Size (ID) 3/8” (9.5mm) Max Operating Pressure 90 psi (6.2 bar) Air Consumption 4.5 cfm (max @90psi) Drive size 3/8” Square Max No Load Speed 180 rpm @ 90psi Max Torque 60 ft/lb (85 Nm) Air Inlet Size 1/4“BSP Female Sound Pressure Level (LpA dB) 87 dB(A)
  • Page 7 2. ALWAYS wear eye protectors when using the tool - Eye protection must provide protection from flying particles/objects from the front and the side. Ear protectors should also be worn. 3. DO NOT overreach - Keep proper footing and balance at all times. 4.
  • Page 8 5. ALWAYS ensure that the socket is correctly installed before switching on. 6. ALWAYS wear suitable respiratory protection due to the possible presence of asbestos dust from vehicle brake linings. 7. ALWAYS disconnect from the air supply when changing sockets or when the wrench is not required for immediate use to avoid accidental starting 8.

  • Page 9: 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 & topped up with oil. CLARKE air-line oil should be used and the lubricator adjusted to approx 2 drops per minute.
  • Page 10 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.

  • Page 11: Before Use

    1. Remove the plastic blanking plug from the air inlet connection. 2. Pour 2-3 drops of CLARKE airline oil into the oil filling port. This should be done regardless of whether or not a lubricated air supply is to be used.
  • Page 12 THE IMPACT WRENCH ¼ ” male inlet adaptor 1/2” Square Drive Trigger Air exhaust Direction/Speed Control Airline Inlet FITTING THE IMPACT SOCKET WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR USE WITH IMPACT TOOLS. 1.
  • Page 13 ADJUSTING THE DIRECTION AND SPEED 1. To adjust the speed, turn the switch slowly forward until the desired output is achieved. • The three dots (small, medium and large) do not denote a specific power output but are only for reference. •...

  • Page 14: Disconnecting The Air Supply

    4. Soak rusted nuts/bolts in penetrating oil, and break rust seal before twisting off with the wrench. WARNING: ENSURE THAT THE CORRECT SOCKET IS BEING USED FOR THE NUTS/BOLTS ON YOUR PARTICULAR VEHICLE. AN INCORRECT SOCKET SIZE IS LIKELY TO DAMAGE THE HEADS OF THE BOLTS/NUTS. TIGHTENING A NUT/BOLT 1.
  • Page 15 THE HAMMER/CHISEL Retaining spring Trigger Air Inlet Male inlet adaptor Chisels (flat & pointed) FITTING THE CHISEL 1. Select which chisel is best suited to the task. 2. First remove the retaining spring from the nose by unscrewing it. • Use the inboard lug to gain purchase.
  • Page 16 USING THE AIR HAMMER 1. Hold the tool firmly, then bring the tool towards the work at an angle of approximately 60-70 degrees. 2. Squeeze the trigger with the chisel in light contact with the work. • The chisel speed is controlled by squeezing the trigger.

  • Page 17: Setting The Direction Of Rotation

    THE REVERSIBLE RATCHET WRENCH NO DESCRIPTION NO DESCRIPTION Forward/Reverse Switch Air Inlet port Square Drive Shaft Male inlet adaptor Trigger SETTING THE DIRECTION OF ROTATION WARNING: ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING BEFORE SETTING THE DIRECTION CONTROL. To select the direction of rotation turn the direction control as follows.
  • Page 18 FITTING SOCKETS AND USING THE AIR RATCHET 1. Select the socket you require and push it onto the square drive shaft. • It clicks into place when secure. 2. Place the socket over the nut/bolt. • Take care that the socket is firmly engaged.
  • Page 19 THE DIE GRINDER NO DESCRIPTION NO DESCRIPTION 17mm collet wrench Air Exhaust Deflector 11mm collet wrench Air Inlet Trigger Grinding stones (3mm/6mm shank) Male Connector Speed Control Collet retaining screw cap INSTALLING THE COLLET 1. Select the grinding stone you require.

  • Page 20: Adjusting The Speed

    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.

  • Page 21: Maintenance

    Run a few drops of CLARKE airline 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.
  • Page 22 3. 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. You may prefer to take the tool to your CLARKE dealer if internal maintenance is required.

  • Page 23: Troubleshooting

    (5 to 50 metres) etc. Contact your CLARKE dealer for further information or CLARKE International Service Department on 01992 565333. CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer. Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
  • Page 24 COMPONENT PARTS - IMPACT WRENCH Description No Description Main housing Gasket O-ring Front housing Trigger Grease cap Gasket E-ring O-ring Bearing Switch Rear plate Spring Cylinder Steel ball Bolt O-ring Rotor Rear cover Spring Set screw Rotor blade Exhaust deflector Front plate Cushion Bearing...
  • Page 25 PARTS DIAGRAM - IMPACT WRENCH Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
  • Page 26 PARTS LIST & DIAGRAM -AIR CHISEL Description No Description Main housing O-ring Valve seat Valve stem Valve plate Trigger End cap Set pin Piston Air inlet Cylinder Pointed chisel Retainer spring Flat chisel O-ring Valve sleeve Spring Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
  • Page 27 COMPONENT PARTS DIAGRAM-RATCHET WRENCH Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...
  • Page 28 COMPONENT PARTS LIST - RATCHET WRENCH Description No Description Main housing Ring gear Housing liner Gear Trigger Gear pin Roll pin Gear seat O-ring Screw-on cap Bushing Needle bearing O-ring Bushing Valve stem Eccentric shaft Spring Drive bushing O-ring Ratchet housing Screw cap Ratchet yoke Nipple...
  • Page 29 Contact your CLARKE dealer or the CLARKE International Service Department for further information. A wide range of 1/2” square drive socket sets is available in the CLARKE catalogue. CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
  • Page 30 COMPONENT PARTS DIAGRAM - 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 the purpose for which it was intended.

  • Page 31: Declaration Of Conformity

    DECLARATION OF CONFORMITY Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com...

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