Clarke X-Pro CAT205 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 ISS 1
1/4”AIR RATCHET WRENCH
MODEL NO: CAT205
PART NO: 3120522

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INTRODUCTION
Thank you for purchasing this CLARKE Air Ratchet Wrench which is ideally
suited to quick removal and installation of nuts, bolts, and other fasteners
where space is limited.
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.
SPECIFICATION
Model Number CAT205
Part Number 3120522
Drive Type 1/4” Square
Max Torque 30 ft/lb (41 Nm)
Dimensions (L x W x H) 176 x 49 x 41 mm
Weight 0.55 kg
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption Average 4 cfm
Max No Load Speed 200 rpm
Reverse Action Yes
Air Inlet Size 1/4“ BSP female
Sound Pressure Level (LpA dB) 86 dB(A)
Sound Power Level (LwA dB) 97 dB(A)
Uncertainty Factor K=3
Vibration Levels 3.78 m/s2 (uncertainty factor K= 1.5m/s2)

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

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6. DO NOT exceed the maximum pressure for the tool of 90 psi / 6.2 bar.
7. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
8. Keep the air supply hose away from heat, oil and sharp edges.
9. DO NOT use the tool for any purpose than that described in this manual.
10. DO NOT fit the tool to any stand or clamping device that may damage it.
11. DO NOT carry out any alterations or modifications to the tool.
12. 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.
13. NEVER use the tool if it is defective or operating abnormally.
14. This tool should be serviced at regular intervals by qualified service
personnel.
15. Avoid damaging the tool for example by applying excessive force of any
kind.
16. ALWAYS maintain the tool with care. Keep it clean for the best and safest
performance.
17. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
18. DO NOT force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
19. DO NOT remove any labels. Damaged labels should be replaced.
20. 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.
TRANSPORT & STORAGE
1. DO NOT carry the tool by the air hose.
2. Never carry an air tool with your finger on the trigger.
3. 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 A 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.
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.
Set the tool in the OFF position before connecting it to the air supply.
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 by up to 15 psi 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 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.

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PRODUCT OVERVIEW
1 Forward/Reverse Switch 3 Trigger
2 1/4”Square Drive Shaft 4 Air Inlet
5 Airline connector

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BEFORE USE
CONNECTING THE AIRLINE
NOTE: Ensure the air supply is turned off.
1. Remove the travel plug
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. Refer to the
instructions supplied with the mini-
oiler before use.
• A mini oiler helps to prolong the
life of any air tool.
4. Connect a suitable hose. This can
be done using either the male
adaptor supplied or using a mini
oiler from your CLARKE dealer.
5. 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.
6. Connect the other end of the hose to the compressor.
7. 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.
8. 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.
You can fit a whip hose with a quick fit coupling if required (available from
your CLARKE dealer).
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND A 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 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.
• 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
settings.
WARNING: ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING
BEFORE SETTING THE DIRECTION CONTROL.

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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
When not in use, disconnect from the air supply, clean & store in a safe, dry
place.
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 storing, replace the blanking plug on the
airline inlet.
Avoid storing the tool where the temperature is below 0oC.

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MAINTENANCE
DAILY
1. Before use, drain water from the compressed air supply.
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.
3. This procedure should be repeated after every two to three hours of use or
at the start of the working day.
4. Keep the body of the tool clean and free from debris.
WEEKLY
1. Check the air inlet screen filter for
blockage and clean if necessary.
CLEANING
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 CLARKE 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.
PERFORMANCE
Please note that outside factors may effect the operation and efficiency of
the tool, 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
COMPRESSED AIR SUPPLY BEFORE STARTING ANY CLEANING OR
MAINTENANCE PROCEDURES.

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Your 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 it 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. O-rings damaged
or ill-fitting in seat.
1. Return to CLARKE dealer
for repair.

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DECLARATION OF CONFORMITY

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COMPONENT PARTS DIAGRAM

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COMPONENT PARTS LIST
ACCESSORIES
A wide range of accessories are available including filter/regulators,
lubricators, high-pressure hoses (5 to 50 metres) etc.
Contact your CLARKE dealer or the CLARKE International Service Department
for further information.
A wide range of 1/4” square drive socket sets is available in the CLARKE
catalogue.
CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
No Description No Description
1 Main housing 22 Gear seat
2 O-ring 23 Hex nut
3 Valve stem 24 Bushing
4 Spring 25 Needle bearing
5 O-ring 26 Eccentric shaft
6 Screw nut 27 Drive bushing
7 Air inlet 28 Ratchet housing
8 Trigger 29 Ratchet yoke
9Pin 30F/Rknob
10 Bearing 31 Spring
11 Rear plate 32 Sleeve
12 Pin 33 Cushion
13 Rotor 34 Ratchet head
14 Rotor blade 35 Ratchet pawl
15 Cylinder 36 Pin
16 Front plate 37 Spring
17 Steel ball 38 Steel ball
18 Bearing 39 Washer
19 Ring gear 40 Circlip
20 Gear 41 Soft grip
21 Pin 42 Head protector