Clarke Air CAT120 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0420 - ISS 2
43-PC AIR TOOL KIT
MODEL NO: CAT120
PART NO: 3110876

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INTRODUCTION
Thank you for purchasing this CLARKE Air Tool Kit.
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.
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 CAT120 Air Tool Kit should include the following:
AIR TOOLS IN THE KIT
1 x ½” Square Drive Impact Wrench
1 x Air Hammer
1 x Reversible Drill
1 x ¼” Die Grinder
1 x Dual Acting Sander
GENERAL ACCESSORIES
1 x Air Inlet Adaptor (¼”male)
1 x Oil Bottle
1 x Hex Key 4mm
FOR THE DRILL
1 x Chuck key
4 x 6.35 mm Hex shank screwdriver bits:
Sizes: 4 & 6 mm straight; Phillips Nos. 2 & 3
FOR THE DIE GRINDER
5 x Assorted grinding stones - 6 mm shank
5 x Assorted grinding stones - 3 mm shank
1 x Pair of spanners

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FOR THE CHIPPING HAMMER
4 x Chisels with various profiles (10.2 mm locating shank - 125 mm length)
FOR THE DUAL ACTION SANDER
1 x 150 mm Backing Pad (accepts 150 mm self-adhesive sanding discs)
FOR THE IMPACT WRENCH
10 x impact sockets, ½” Square drive sizes: 9,10,11,13,14,17,19,22,24,27 mm
TECHNICAL SPECIFICATIONS
The 5 x air tools supplied in this CAT120 kit have a 1/4” BSP female threaded
connection for use with an maximum air supply pressure of 90 psi (6.2 bar).
IMPACT WRENCH
Air Consumption 8 cfm
Drive size 1/2” square
Max No Load Speed 7000 rpm @ 90psi
Max Torque 230 ft/lb
Sound Pressure Level (LpA dB) 84.4 dB(A)
Sound Power Level (LwA dB) 95.4 dB(A)
Vibration Levels 2.6 m/s2(uncertainty factor K= 0.72m/s2)
Dimensions (L x W x H) & Weight 220 x 75 x 180 mm Weight 2.2 kg
HAMMER/CHISEL
Air Consumption 3-16 cfm (84-452 l/min)
Max Blows per minute 4500
Vibration Levels 14.6 m/s2(uncertainty factor (K= 0.99m/s2)
Sound pressure level 84 dB LpA
Sound power level 95 dB LWA
Dimensions (L x W x H) & Weight 153 x 48 x 152 mm Weight = 1.1 kg

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REVERSIBLE DRILL
Chuck Size 1.5 - 10 mm
Air Consumption 6 cfm
Max Speed 1800 rpm
Sound Pressure Level (LpA dB) 87 dB(A)
Sound Power Level (LwA dB) 98 dB(A)
Vibration Levels 1.2 m/s2 (K= 1.25 m/s2 )
Dimensions (L x W x H) & Weight 191 x 42 x 144 mm Weight 1.15 kg
DIE GRINDER
Air Consumption 4 cfm (1151 l/min)
Max Speed 22000 rpm
Sound Pressure Level (LpA dB) 83.5 dB(A)
Sound Power Level (LwA dB) 94.5 dB(A)
Vibration Levels 1.2 m/s2(K=0.35 m/s2)
Dimensions (L x W x H) & Weight 173 x 46 x 68 mm Weight 0.64 kg
DUAL-ACTING SANDER
Air Consumption @ 6.3 bar 2-16 cfm (56-452 l/min)
Pad size 150 mm
Sound Power Level 98.2 dB LWA
Sound Pressure Level 87.2 dBA
Vibration Level 2.5 m/s2
Uncertainty Factor (K) 1.25 m/s2
Dimensions (L x D x H) & Weight 223 x 73 x 123 mm Weight = 1.81 kg
Max Speed 10,000 rpm

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GENERAL SAFETY WARNINGS
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 & visitors away - Do not let children handle the tools.
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 air tools when
you are tired or under the influence of alcohol, drugs or medication.
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. DO NOT use any type of bottled gas as a source of power for this tool.
5. DO NOT connect the air supply hose with your finger on the trigger.
6. DO NOT exceed the maximum pressure for the air tools 90 psi / 6.2 bar.
7. ALWAYS check hoses for leaks and ensure that all connections are secure.
8. ALWAYS keep the air supply hose away from heat, oil and sharp edges.
9. DO NOT use the tools for any purpose than that described in this manual.
10. DO NOT fit the tools to any stand or clamping device that may damage it.
11. ALWAYS disconnect from the air supply when:
• Performing maintenance
• The tools are not in use.
• The tools will be left unattended.
• Moving to another work area.
12. DO NOT use any tool if it is defective or operating abnormally.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY AND/OR DAMAGE TO PROPERTY.

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13. ALWAYS avoid damaging the tools by applying excessive force.
14. ALWAYS maintain the tools. Keep them clean for the safest performance.
15. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
16. DO NOT force or misuse the tools which will do a better and safer job at the
rate for which they are designed.
17. These tools 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.
IMPACT WRENCH SPECIFIC HAZARDS
1. ALWAYS use the impact wrench as described in these instructions.
2. ALWAYS ensure the wrench is not moving and disconnected from the air
supply when changing sockets etc. Use only impact wrench sockets....DO
NOT use standard sockets.
3. ALWAYS finish tightening nuts with a torque wrench or suitable spanner to
the correct torque as recommended by the vehicle manufacturer.
4. ALWAYS avoid excessive use of the impact wrench. When tightening a nut
or bolt, only allow the wrench to impact briefly to avoid overtightening.
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. DO NOT carry the wrench by the air supply hose.
9. ALWAYS use both hands to control the wrench.
10. ALWAYS ensure the wrench has stopped before putting it down.
AIR HAMMER SPECIFIC HAZARDS
1. Only use accessories designed for use with this tool.
2. DO NOT use any of the chisels supplied as a hand struck tool.
3. DO NOT use blunt chisels which require excessive pressure and can break
from fatigue. Always use sharp tools.
4. DO NOT mis-use the tool by prising which can result in a broken chisel.
5. ALWAYS ensure there are no hidden electrical cables, gas pipes etc, which
could cause a hazard if damaged by action of the chisels.

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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
& topped up with oil. CLARKE air-line 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.
Air compressors used with the tool must comply with the appropriate
European Community Safety Directives.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SYSTEMS.

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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 air tool. It is
recommended that air pressure to this tools does not exceed 90 psi at the tool
when running. Higher pressures and unclean air will shorten the life of an air
tool due to faster wear and is a possible safety hazard.
CONNECTING THE TOOLS TO THE AIR LINE
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.
3. If required, connect an in-line mini
oiler to the tool to prolong the life
of any air tool.
4. Connect a suitable hose as shown
or use the connector supplied to
connect directly to the hose.
• PTFE tape may be useful for
sealing threaded connections
5. Connect the other end of the hose
to the compressor.
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 hold
the throttle open 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 air tool is now ready for use.

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THE IMPACT WRENCH
FITTING THE IMPACT SOCKET
1. Select the impact socket you
require, which must be in good
condition and fit the tool exactly.
2. Push the socket onto the square
drive shaft as shown.
11/2”SquareDrive 5
¼” female inlet adaptor
2 Forward/reverse button 6 Handle
3 Trigger 7 Oil port
4SpeedControl
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR
USE WITH IMPACT TOOLS.

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ADJUSTING THE DIRECTION AND SPEED
THE FORWARD/REVERSE BUTTON SHOULD BE USED AS FOLLOWS:
1. For normal tightening, the impact wrench should be operated in the
forward (F) direction.
2. For loosening, the he impact wrench should be operated in the reverse (R)
direction.
NOTE: Where the torque setting is critical, the final tightening of nuts or
bolts, must be by hand using a correctly calibrated torque
wrench.
ADJUSTING THE POWER
To adjust the power, set the air regulator to one of the 4 settings available.
1 (Low) - 4 (High)
USING THE IMPACT WRENCH
LOOSENING A WHEEL NUT/BOLT
1. Remove any wheel trim, before selecting the appropriate socket and
placing firmly on the square drive of the wrench.
WARNING: WAIT UNTIL THE WRENCH HAS STOPPED ROTATING BEFORE
OPERATING THE FORWARD/REVERSE SWITCH.
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR
USE WITH IMPACT TOOLS.

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2. With the FORWARD/REVERSE switch in the REVERSE running position, and
holding the wrench firmly in BOTH HANDS, pull the trigger. The nut/bolt will
be impacted repeatedly until it is loosened.
IMPORTANT: Release the trigger as soon as the nut begins to loosen.
3. Jack up the vehicle according to the vehicles handbook so that the wheel
is clear of the ground, then proceed to fully undo the wheel nuts/bolts.
4. Soak rusted nuts/bolts in penetrating oil, and break rust seal before twisting
off with the wrench.
TIGHTENING A NUT/BOLT
1. Start the nut by hand, ensuring it is not cross threaded, then with the
appropriate socket installed on the wrench, place it on the nut/bolt.
2. With the FORWARD/REVERSE selector in the clockwise (FORWARD) running
position and holding the wrench firmly in BOTH HANDS, pull the trigger.
3. Run each nut/bolt up in turn until it is ‘nipped’ up only - do not tighten.
When all nuts are nipped up, tighten progressively by pulling the trigger fully
and allowing the action to operate briefly to prevent overtightening.
4. ALWAYS finish tightening with a torque wrench. The weight of the vehicle
will need to be placed on the wheel to prevent it from rotating while the
nuts are tightened. Ensure the final torque applied to the nuts/bolts meets
the vehicle manufacturer’s recommendations.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the hose until the supply is isolated at a shut-off valve.
2. Once the pressure has been isolated, disconnect the air supply hose.
3. Shut down the compressor at the end of the session.
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.

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THE HAMMER/CHISEL
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.
3. Insert the chisel into the air
hammer as shown.
4. Replace the retaining spring.
• Use the lugs to help tighten.
1Outboardlug 5 ¼” female inlet adaptor
2 Retaining spring 6 Speed controller
3 Inboard lug Air Inlet 7 Chisels (flat & pointed)
4 Trigger

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ADJUSTING THE FORCE
Chisel force may be adjusted by
turning the regulator knob, located at
the base of the handle.
• Turn anticlockwise to increase
force.
• Turn clockwise to reduce the
force.
USING THE CHIPPING 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.
3. Move slowly across the work
surface. To remove scale, rust or
other contaminants, only a light
force should be required.
4. Release the trigger to stop
operation whilst maintaining contact with the work.
5. The tool may operate briefly after the trigger is released.
NOTE: The retaining spring has a life expectancy, depending upon the
intensity of usage. It is recommended that you procure a spare
spring for use in the event of failure occurring during the course of
a particular job.
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.
3. Shut down the compressor at the end of the work session.

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THE REVERSIBLE DRILL
INSERTING/REMOVING THE DRILL BIT
1. Open the chuck jaws
by inserting the
chuck key in one of
the holes in the
chuck and turning it
as shown.
• Make sure that the
head of the chuck
key is located on
the cog barrel of
the chuck.
NO DESCRIPTION NO DESCRIPTION
1 Chuck 4 Handle
2Trigger 5
¼” female inlet adaptor
3 Direction control switch

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2. Open sufficiently to take the drill bit.
3. Place the drill bit in the jaws of the chuck as far as it will go.
4. Close the chuck jaws and tighten to grip the drill bit by turning the chuck
key as shown.
5. Make sure that the chuck jaws are fully closed and that the drill bit is firmly
held.
DIRECTION CONTROL SWITCH
The direction control switch should be used as follows.
1. For normal drilling the drill must be
operated in the forward (F)
direction.
2. If the drill bit jams whilst drilling,
release the trigger switch.
3. When the drill has come to a
complete stop, move the direction
control switch to the reverse (R)
position.
USING THE REVERSIBLE DRILL
1. Squeeze the trigger switch to start the air drill.
2. Wait until the air drill is running at its maximum speed before applying it
carefully to the workpiece.
3. Release the trigger switch to stop the air drill.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the hose until the supply is isolated at a shut-off valve.
2. Once the pressure has been isolated, disconnect the air supply hose.
3. Shut down the compressor at the end of the session.
WARNING: WAIT UNTIL THE CHUCK HAS STOPPED ROTATING BEFORE
OPERATING THE DIRECTION CONTROL SWITCH.
WARNING: MAKE SURE THAT THE CHUCK KEY HAS BEEN REMOVED
BEFORE USING THE DRILL.

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THE DIE GRINDER
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 is already
installed in the grinder.
NO DESCRIPTION NO DESCRIPTION
1 Collet 4 Trigger
2 Spindle 5 ¼” female inlet adaptor
3Triggerlock

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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.
OPERATING THE DIE GRINDER
1. Slide the throttle locking lever
forward while squeezing the
trigger against the body of the
tool.
2. Allow the tool to reach full working
speed before presenting the
grinding stone to the workpiece.
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.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the hose until the supply is isolated at a shut-off valve.
2. Once the pressure has been isolated, disconnect the air supply hose. Shut
down the compressor at the end of the session.

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THE DUAL ACTION SANDER
FITTING THE BACKING PAD
1. Turn spindle lock until the knurled portion contacts the flat surface on the
spindle.
2. Thread the backing pad into the
spindle, by grasping the balancer,
with one hand and the pad with
the other. Do not over tighten.
3. Now turn the spindle lock so that
the knurled portion is away from
the flat on the spindle, and the
spindle turns freely.
NO DESCRIPTION NO DESCRIPTION
1 Trigger 4 Locking nut
2 Speed control 5 Backing pad
3Balancer 6
¼” female inlet adaptor

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4. DO NOT operate tool with spindle in locked mode as performance would
be severely affected and a hazardous situation may result.
FITTING THE SANDING SHEET
1. Peel off the back of the self adhesive sanding sheet and stick it to the
backing pad.
ADJUSTING THE SPEED
Adjust the operating speed if
required, by twisting the speed
control.
• Clockwise to increase the
sanding speed.
• Anticlockwise to decrease the
sanding speed.
USING THE SANDER
1. Place the sander on the workpiece and press down on the trigger to start
the sander.
2. Release pressure from the trigger to stop the sander.
3. Always ensure the sander has stopped before putting it down on any
surface after use.
4. Avoid contact with the moving sanding pad and wear suitable gloves to
protect the hands.
5. Never start the sander unless the abrasive pad is applied to the workpiece.
6. Always wear a face mask when using the sander as protection from
airborne particles of sanded material. Avoid disturbing existing dust and
minimise the scattering of dust in the workplace environment. Take steps to
control the dust at the point of emission.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the hose until the supply is isolated at a shut-off valve.
2. Once the pressure has been isolated, disconnect the air supply hose.
3. Shut down the compressor at the end of the session.

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MAINTENANCE
DAILY
1. Before use, drain water from the airline filter 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
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.
3. This procedure should be repeated after every two to three hours of use, or
at the start of the working day.
4. Check the air inlet screen filter for blockage and clean if necessary.
5. Keep the body of the tool clean and free from debris.
CLEANING & OVERHAUL
1. Grit or gum deposits in the tool may reduce efficiency.
2. After extensive use, remove the inlet screen filter and flush out the
mechanism with gum solvent oil or an equal mixture of air-line oil and
paraffin. Allow to dry before use.
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.
4. The air tool may be dismantled by unfastening the bolts and removing the
rear cover prior to replacing any worn or damaged parts.
5. While the impact wrench or air hammer is a dismantled state, it may be
desirable to grease the hammer mechanism and applying a small amount
of good quality bearing grease.
This may be better left to your CLARKE dealer.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE.