Clarke X-Pro CAT202 Installation and operation manual

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

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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 CAT202 air tool kit should include the following:
AIR TOOLS
1 x ½” Reversible Ratchet Wrench
1 x Air Hammer
1 x ½” Square Drive Impact Wrench
1 x ¼” Die Grinder
1 x Blow Gun
GENERAL ACCESSORIES
FOR THE RATCHET WRENCH
FOR THE AIR HAMMER:
• 5 x Air Inlet Adaptors (¼”male) • 1 x Roll PTFE tape
• 1 x Oil Bottle • Tyre pressure gauge
• Tyre inflating nozzle
• 1 x 3/8 female to 1/2” male
adaptor
• 1 x Flat Chisel • 1 x Pointed chisel

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FOR THE IMPACT WRENCH:
FOR THE DIE GRINDER:
FOR THE BLOW GUN:
PRODUCT SPECIFICATIONS
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
• 5 x Assorted Stones,
6mm (1/4”) shank
• 2 x wrenches
(11 and 17mm)
• 5 x Assorted Stones,
3mm (1/8”) shank
• 1 x 1/8” (3mm) collet
• Air Inlet Adaptor (¼”female) • 1 x Safety Nozzle
• 2 x Nozzles (sports equipment) • 1 x Tapered Nozzle
• 1 x Rubber nozzle •
Min. Hose Size (ID) 3/8” (9.5mm)
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption 6.5 cfm (average)
Drive size 1/2” Square
Max No Load Speed 8000 rpm @ 90psi
Max Torque 650 ft/lb (885 Nm)
Torque settings 1) - 185 ft/lbs
2) - 330 ft/lbs
3) - 650 ft/lbs
4) - In reverse - 670 ft/lbs
Air Inlet Size 1/4“BSP Female

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DIE GRINDER
Sound Pressure Level (LpA dB) 87 dB(A)
Sound Power Level (LwA dB) 98 dB(A)
Vibration Levels 4.35 m/s2(uncertainty factor K= 1.5m/s2)
Weight 2.49 kg
Wrench Dimensions (L x W x H) 197 x 190 x 68 mm
Dimensions (L x W x H) 169 x 37 x 66 mm
Weight 0.39 kg
Collet size 1/4“and 1/8”
Air Inlet Size 1/4“BSP (female)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4 cfm (average)
No Load Speed 25000 rpm @ 90psi
Speed Settings and rpm Setting 1 - 8,300 rpm
Setting 2 - 13,000 rpm
Setting 3 - 22,000 rpm
Setting 4 - 25,000 rpm
Sound Pressure Level (LpA dB) 88 dB(A)
Sound Power Level (LwA dB) 98 dB(A)
Vibration Levels 2.9 m/s2

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AIR HAMMER/CHISEL
BLOW GUN
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/s2(uncertainty factor K= 1.5m/s2)
Sound pressure level 98 dB LpA
Sound power level 111 dB LWA
(uncertainty factor K 3 dB
Dimensions (L x W x H) 130 x 42 x 153 mm
Weight 1.05 kg
Chisel size Overall length = 125 mm
Body width = 11.6 mm
Shank length = 42 mm
Shank width = 10.2 mm
Min. Hose Size (ID) 3/8” (9.5mm)
Max Operating Pressure 90 psi (6.2 bar)
Dimensions (L x W x H) 133 x 19 x 176 mm
Weight 0.177 kg

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RATCHET WRENCH
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.
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)
Sound Power Level (LwA dB) 98 dB(A)
Vibration Levels 4.35 m/s2(uncertainty factor K= 1.5m/s2)
Weight 1.18 kg
Wrench Dimensions (L x W x H) 265 x 47 x 53 mm
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY AND/OR DAMAGE TO PROPERTY.

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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.
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.

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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.
BLOW GUN SPECIFIC HAZARDS
1. DO NOT use the blow gun if it is defective or operating abnormally.
2. ALWAYS maintain the blow gun with care. Keep it clean for the best and
safest performance.
3. DO NOT discharge this blow gun at any persons or animals.
4. DO NOT insert into any part of yours or anyone elses body.
5. DO NOT point directly at a person’s skin or at a fire.
6. DO NOT carry the blow gun by the air hose or with your finger on the
trigger.

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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.
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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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. 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.

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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.
3. If required, connect an in-line mini oiler to the tool.
• A mini oiler helps to prolong the life of any air tool.
4. Connect a suitable hose as shown
or use the snap 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.
8. 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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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 4
¼” male inlet adaptor
2 Trigger 5 Air exhaust
3 Direction/Speed Control 6 Airline Inlet
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
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.
• Setting 1 (small dot) is the least
amount of power while setting 3
(large dot) is the most powerful.
• The wrench operates at maximum power in reverse. This setting is for
releasing threaded fasteners which may be tight.
NOTE: Where the torque setting is critical, the final tightening of nuts or
bolts, must be by hand using a correctly calibrated torque
wrench.
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.
2. With the FORWARD/NEUTRAL/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.
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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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/NEUTRAL/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 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 impact wrench.
3. Shut down the compressor at the end of the work 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.
1 Retaining spring
2Trigger
3 Air Inlet
4 Male inlet adaptor
5 Chisels (flat & pointed)

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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.
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 RATCHET WRENCH
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).
NO DESCRIPTION NO DESCRIPTION
1 Forward/Reverse Switch 4 Air Inlet port
2 Square Drive Shaft 5 Male inlet adaptor
3Trigger
WARNING: ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING
BEFORE SETTING THE DIRECTION CONTROL.

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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.
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.
THE BLOW GUN
The blow gun can be used with any of the nozzles listed on page 2.
A 13mm wrench will be required to remove the nozzle already fitted. A hose
(not supplied) will be required to connect to the tyre inflating 2-way chuck
nozzle.
The 0-50psi linear pressure gauge is for indication only and if accuracy is
required, the pressure should be checked with a calibrated pressure gauge.

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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 17mm collet wrench 5 Air Exhaust Deflector
2 11mm collet wrench Air Inlet 6 Trigger
3 Grinding stones (3mm/6mm shank) 7 Male Connector
4 Speed Control 8 Collet retaining screw cap

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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.
ADJUSTING THE SPEED
1. Set the tool speed by rotating the
control to one of the four settings.
• The numbers on the speed
control knob indicate the
speed setting when aligned
with the reference mark on the
air inlet +/-10%):
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.
18,300 rpm
213,000 rpm
322,000 rpm
425,000 rpm