Clarke X-Pro CAT199 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 - ISS1
½”AIR RATCHET WRENCH
MODEL NO: CAT199
PART NO: 3120516

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INTRODUCTION
Thank you for purchasing this CLARKE Ratchet Wrench which is ideally suited to
quick removal and installation of nuts, bolts, and other fasteners where space
is limited.
Please read all of the safety and operating instructions carefully before using
this product. 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.
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.
Model Number CAT199
Part Number(s) 3120516
Min. Hose Size (ID) 1/4” BSP
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption 4 cfm (max @90psi)
Drive size 1/2” 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) 86 dB(A)
Sound Power Level (LwA dB) 97 dB(A)
Vibration Levels 3.78 m/s2 (uncertainty factor K= 1.5m/s2)
Weight 1.07 kg
Wrench Dimensions (L x W x H) 238 x 53 x 47 mm

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GENERAL SAFETY RULES
THE 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 AIR POWERED TOOLS
1. Stay alert and use common sense - do not operate the 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. Ear
protectors should also be worn.
3. DO NOT overreach - Keep proper footing and balance at all times.
4. NEVER use oxygen, CO2, combustible gases or 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 tool of 90 psi / 6.2 bar.
7. ALWAYS keep the air hose away from heat, oil and sharp edges.
8. DO NOT fit the air tool to a stand or clamping device that may damage it.
9. Check hoses for leaks or worn condition before use and ensure that all
connections are secure.
10. DO NOT use the tool for any purpose than that described in this manual.
11. DO NOT carry out any alterations or modifications to the air tool.
12. ALWAYS disconnect from the air supply when:
• Performing any maintenance.
• The air tool is not in use.
• The air tool will be left unattended.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• Moving to another work area.
13. DO NOT use the air tool if it is defective or operating abnormally.
14. Avoid damaging the air tool for example by applying excessive force of
any kind.
15. ALWAYS maintain the air tool with care. Keep it clean for the best and
safest performance.
16. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
17. DO NOT force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
18. This air 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.
19. DO NOT carry the air tool by the air hose.
20. DO NOT carry the air tool with your finger on the trigger.
21. When not in use the air tool must be disconnected from the air supply and
stored in a dry place out of the reach of children.

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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 air tools in good condition but should be regularly checked
and topped up with oil. CLARKE airline oil should be used and the lubricator
be adjusted to approx 2 drops per minute.
Use only clean, dry, regulated compressed air as a power source.
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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Air compressors used with the tool must comply with the appropriate
European Community Safety Directives.
The air hose must be rated at least 150% of the maximum operating pressure of
the tool.
For optimum performance it is recommended that a 3/8” ID airline hose is
used.
A build-up of moisture or oil in the air compressor will accelerate wear and
corrosion in the air 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 to maintain air pressure at the
tool.
Never exceed the maximum operating pressure for the air tool. It is
recommended that air pressure to this tool does not exceed 90 psi (6.2 Bar) at
the air tool when running. Higher pressures and dirty air will shorten the life of
the tool due to faster wear and is a possible safety hazard.
Check hoses for wear or damage before use.
OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Direction Control 4 Airline Inlet
2 1/2” Square Drive 5 Airline adaptor
3Trigger

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the travel plug and connect either a suitable hose directly or
using the male adaptor supplied.
2. If required, connect an in-line mini
oiler to the tool.
• A mini oiler helps to prolong the
life of any 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 airline connector or
via the hose at the nearest
connection to the air supply.
4. Connect the other end of the hose
to the compressor.
5. Turn on the air supply and check
for air leaks. Rectify any found
before proceeding. Set the
working pressure to 90psi/6.2 bar
for best performance
• PTFE tape may be useful for
sealing threaded connections.
Your air tool is now ready for 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.

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OPERATION
SETTING THE DIRECTION OF ROTATION
To select the direction of rotation turn
the direction control as follows.
• For tightening bolts/nuts, turn
the direction control anti-
clockwise to F (Forward).
• For loosening bolts/nuts, turn the
direction control clockwise to R
(Reverse).
FITTING THE SOCKETS AND USING THE WRENCH
1. Select the socket required and
push it onto the square drive shaft.
• It clicks into place when secure.
2. Place the socket over the nut.
• Take care that the socket is
firmly engaged.
3. Squeeze the trigger against the
body of the tool to start.
4. Release the trigger to stop the tool.
5. ALWAYS ensure the tool has stopped before putting it down.
6. When releasing very tight fastenings initially break loose by hand. Squeeze
the trigger and the air tool will complete the job.
7. If necessary, use penetrating oil to assist in freeing off rusted fasteners.
8. When assembling, start turning fasteners by hand, then set the rotation
forward or reverse. Apply the tool gently and squeeze the trigger to tighten
with power.
9. Final tightening should be completed by hand to the required torque
values.
WARNING: ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING
BEFORE SETTING THE DIRECTION OF ROTATION.

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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 from
the air tool.
3. Shut down the compressor at the end of the work session and drain daily as
recommended.
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.
Store the tool safely in its box in a dry, secure environment. When storing,
replace the blanking plug on the airline inlet once the airline has been
disconnected.
Avoid storing the air tool where the temperature is below 0oC.

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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 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. Only then should you operate the tool.
3. This procedure should be repeated after every two to three hours of use, or
at the start of the working day.
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 in the tool
may reduce efficiency.
3. After extensive use, remove the
inlet screen filter and flush out the
mechanism with gum solvent oil or an equal mixture of CLARKE air-line oil
and paraffin. Allow to dry before use.
4. 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.
PERFORMANCE
Please note that outside factors may affect the tool’s 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.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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Your CLARKE air 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.
TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Motor parts worn.
2. Worn or sticking
mechanism due to
lack of lubricant.
1. Return to CLARKE dealer
for repair.
2. 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. Air-line regulator in
closed position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
blockage and clean if
necessary. Drip a few
drops of air tool lubricat-
ing oil into air inlet.
2. Adjust in-line 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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PARTS LIST
No Description No Description
1 Main housing 25 Ring gear
2 Housing liner 26 Gear
3Trigger 27GearPin
4Bolt 28Gearseat
5 O-ring 29 Screw nut
6 Bushing 30 Needle bearing
7 O-ring 31 Bushing
8 Valve stem 32 Eccentric shaft
9 Spring 33 Drive bushing
10 O-ring 34 Ratchet housing
11 Screw 35 Ratchet yoke
12 Nipple 36 F/R knob
13 Exhaust deflector 37 Sleeve
14 Air inlet 38 Spring
15 Decoration ring 39 Washer
16 Bearing 40 Ratchet head
17 Rear plate 41 Pin
18 Rotor 42 Ratchet pawl
19 Rotor blade 43 Washer
20 Cylinder 44 Circlip
21 Set pin 45 Spring
22 Front plate 46 Steel ball
23 Bearing 47 Spring
24 Cushion 48 Steel ball

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PARTS DIAGRAM

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DECLARATION OF CONFORMITY

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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 the Clarke International
Service Department.
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.
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.