Clarke CAT120 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC 0520 - ISS 3
43 PIECE AIR TOOL KIT
MODEL NO: CAT120
PART NO: 3110876

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INTRODUCTION
Thank you for purchasing this CLARKE product.
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.
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 effect your statutory rights.
ENVIRONMENTAL PROTECTION
Recycle unwanted materials instead of disposing of them as
waste. All tools, accessories and packaging should be sorted,
taken to a recycling centre and disposed of in a manner which is
compatible with the environment.

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TABLE OF CONTENTS
INTRODUCTION ......................................................................... 2
GUARANTEE ............................................................................... 2
ENVIRONMENTAL PROTECTION ................................................ 2
TABLE OF CONTENTS ................................................................. 3
GENERAL SAFETY RULES ............................................................ 4
LIST OF CONTENTS ..................................................................... 6
Accessories ...................................................................................................... 6
AIR SUPPLY ................................................................................. 7
Recommended Air Supply Connection ...................................................... 7
THE IMPACT WRENCH ............................................................... 8
Before Use ........................................................................................................ 9
Using The Forward/reverse Button ................................................................ 10
Fitting the Impact Socket ............................................................................... 10
Adjusting the Power ....................................................................................... 11
Operating The Impact Wrench ..................................................................... 11
Disconnecting the air supply ......................................................................... 11
THE DUAL ACTION SANDER ...................................................... 12
Before Use ........................................................................................................ 13
Fitting The backing pad ................................................................................. 13
Fitting The Sanding Sheet ............................................................................... 13
Adjusting The Speed ....................................................................................... 14
Using The Sander ............................................................................................. 14
THE CHIPPING HAMMER ........................................................... 15
Before Use ........................................................................................................ 16
Fitting the chisel .............................................................................................. 16
Adjusting the force ......................................................................................... 17
Using the Chipping Hammer ......................................................................... 17
THE DIE GRINDER ....................................................................... 18
Before Use ........................................................................................................ 19
Collets ............................................................................................................... 19
Fitting the grinding point or stone ................................................................. 20
Using the Die Grinder ...................................................................................... 20
THE REVERSIBLE DRILL ............................................................... 21
Before Use ........................................................................................................ 22
Inserting/Removing the Drill Bit ...................................................................... 22
Direction Control Switch ................................................................................ 23
Using The Reversible Drill ................................................................................ 23
AFTER USE .................................................................................. 24
Disconnecting The Air Supply ........................................................................ 24
Storage ............................................................................................................. 24
MAINTENANCE .......................................................................... 25
SPECIFICATIONS - GENERAL ................................................... 26
SPECIFICATIONS - MODEL SPECIFIC ........................................ 27
VIBRATION EMISSIONS ............................................................. 28
DECLARATION OF CONFORMITY ............................................. 30
NOTES ........................................................................................ 31

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GENERAL SAFETY RULES
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.
5. Keep the air supply hose away from heat, oil and sharp edges.
6. Do not fit the tool to any stand or clamping device that may damage the
tool.
USE
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.
3. Always wear ear protectors when using the tool.
4. Do not overreach - Keep proper footing and balance at all times.
5. Never use any type of bottled gas as a source of power for the tool.
6. Do not connect the air supply hose with your finger on the trigger of the
tool.
7. Do not exceed the operating pressure for the tool: 90 psi / 6.2 bar.
8. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
9. Do not use the tool for any other purpose than that described in this book.
10. Do not carry out any alterations or modifications to the tool.
11. Always disconnect from the air supply when:
• Performing any maintenance
• The tool is not in use.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.
CAUTION: THESE RULES APPLY TO ALL TOOLS IN THIS KIT.

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• The tool will be left unattended.
• Moving to another work area.
• Passing the tool to another person.
12. Never use the tool if it is defective or operating abnormally.
13. The tool should be serviced at regular intervals by qualified service
personnel.
14. Avoid damaging the tool for example by applying excessive force of any
kind.
15. ALWAYS maintain the tool with care. Keep it clean for 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. Do not remove any labels. Damaged labels should be replaced.
19. 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.
20. NEVER use standard sockets. These may shatter with serious consequences.
Use ONLY Impact sockets.
TRANSPORTATION
1. Never carry the tool by the air supply hose.
2. Never carry the tool with your finger on the trigger.
STORAGE
1. When not in use the tool must be disconnected from the air supply and
stored in a dry place out of the reach of children (preferably in a locked
cabinet).
2. Avoid storing the tool in environments where the temperature is below 0oC.

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LIST OF CONTENTS
1 x 3/8” Reversible Drill
1 x Die Grinder c/w 1/8” & 1/4” Collets
1 x Chipping Hammer
1 x Dual Action Sander
1 x ½” Drive Impact Wrench
ACCESSORIES
1 x Air Inlet Adaptor
1 x Oil Bottle
1 x Hex Key, 4 mm
FOR THE DRILL:
2 x 6.35mm Slotted Screw Driver Bits: 4 & 6 mm
2 x 6.35mm Philips Screw Driver Bits: 2 & 3
1 x Chuck Key
FOR THE DIE GRINDER:
5 x Assorted Mounted Points, 6.35 (1/4") mm Shank:
5 x Assorted Mounted Points, 3.175mm (1/8")Shank:
2 x Spanners
FOR THE CHIPPING HAMMER:
1 x Flat Chisel
1 x Flat Chisel, Inverted V
1 x Flat Chisel, Inverted C
1 x Pointed
10.2 mm dia shank x 125 mm length
1 Chisel Retaining Clip
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 mm, 10 mm, 11 mm,13 mm,
14 mm, 17 mm, 19 mm, 22 mm, 24 mm, 27 mm
Extension Bar

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AIR SUPPLY
• Use only clean, dry, regulated compressed air as a power source for
the tool.
• 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.
• Never exceed the operating pressure for the tool.
AIR HOSE
• The air hose must be rated at least 150% of the operating pressure of
the tool.
RECOMMENDED AIR SUPPLY CONNECTION
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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THE IMPACT WRENCH
NO DESCRIPTION NO DESCRIPTION
1 1/2” Square Drive Anvil 5 1/4” BSP (Female Air Inlet)
2 Forward / Reverse Button 6 Handle
3 Trigger 7 Oil Port
4 Speed Control
1
2
3
45
6
7

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the travel plug from the 1/
4” BSP (Female Air Inlet) as shown.
2. Pour 2-3 drops of CLARKE airline oil
into the air inlet. This should be
done regardless of whether or not
a lubricated air supply is to be
used.
3. Connect a suitable hose to the
impact wrench as shown.
• Use the adapter supplied if
required.
4. Connect the other end of the hose
to the compressor.
5. Your impact wrench 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
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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USING THE FORWARD/REVERSE BUTTON
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 impact wrench should be operated in the reverse (R)
direction.
FITTING THE IMPACT SOCKET
1. Select the impact socket you
require.
2. Push the impact socket onto the
anvil as shown.
WARNING: WAIT UNTIL THE ANVIL HAS STOPPED ROTATING BEFORE
OPERATING THE FORWARD/REVERSE BUTTON.
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE ACCESSORIES DESIGNED FOR USE
WITH IMPACT TOOLS.
FORWARD REVERSE

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ADJUSTING THE POWER
To adjust the power, set the air regulator
to one of the 4 settings available.
1 (Low) - 4 (High).
OPERATING THE IMPACT WRENCH
1. Locate the socket over the nut to
be tightened or loosened.
2. Squeeze the trigger to start the
impact wrench.
3. Release the trigger switch to stop
the Impact Wrench.
• The anvil will continue to rotate
briefly after the trigger has been
released.
DISCONNECTING THE AIR SUPPLY
Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released.
1. Refer to the compressor instruction book for the procedures to shut down
and release the compressed air.
2. Once the pressure has been released, disconnect the air supply hose from
the Impact Wrench.
3. Store the Impact Wrench safely in its box in a dry, secure environment.
WARNING: MAKE SURE THAT THE CHUCK KEY HAS BEEN REMOVED
BEFORE USING THE DRILL.

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THE DUAL ACTION SANDER
NO DESCRIPTION NO DESCRIPTION
1Trigger 4LockingNut
2 Speed Control 5 Backing Pad
3 Balancer 6 1/4” BSP (Female Air Inlet)
1
2
34
5
6

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the travel plug from the bottom of the tool.
2. Pour 2-3 drops of CLARKE airline oil into the air inlet. This should be done
regardless of whether or not a lubricated air supply is to be used.
3. Connect a suitable hose to the
tool as shown.
• Use the adapter supplied if
required.
4. Connect the other end of the hose
to the compressor.
You can fit a whip hose with a quick fit
coupling if required (available from
your Clarke dealer.)
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.
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.
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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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.

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THE CHIPPING HAMMER
NO DESCRIPTION NO DESCRIPTION
1 Retainer spring 5 Speed controller/air regulator
2 Main body 6 Outboard lug
3 Trigger 7 Inboard lug
4 1/4” BSP (Female Air Inlet) 8 Chisel set
12
3
45
6
7
8

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the travel plug from the
bottom of the tool as shown.
2. Pour 2-3 drops of CLARKE airline oil
into the air inlet. This should be
done regardless of whether or not
a lubricated air supply is to be
used.
3. Connect a suitable hose to the
tool as shown.
• Use the adapter supplied if
required.
4. Connect the other end of the hose
to the compressor.
You can fit a whip hose with a quick fit
coupling if required (available from
your Clarke dealer.)
FITTING THE CHISEL
1. First remove the spring from the
nose by unscrewing it.
• Use the inboard lug to gain
purchase.
2. Insert the end of the chisel into the
chipping hammer.
3. Replace the spring, as shown.
• Use the outboard lug to tighten.
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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ADJUSTING THE FORCE
Chisel force may be adjusted by
turning the Speed controller/air
regulator located at the base of the
handle grip.
• Turn anticlockwise to increase
force.
• Turn clockwise to reducethe
force.
USING THE CHIPPING HAMMER
1. Hold the tool with one hand
around the handle and one hand
around the barrel, then bring the
tool towards the work at an angle
of approximately 60-70 degrees.
2. Pull the trigger with the chisel in
light contact with the work.
3. Move slowly across the work
surface and proceed to remove
scale, rust or other contaminants, a light force only should be required.
4. Release the trigger to stop operation, whilst maintaining contact with the
work, noting that the tool may impact briefly after the trigger is released.
NOTE: The Retaining Spring has a life expectancy, depending upon the
intensity of usage. It is strongly recommended that you obtain one
or two spare springs, for use in the event of failure occurring
during use. These are available from the Clarke Spares
department.

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THE DIE GRINDER
NO DESCRIPTION NO DESCRIPTION
1 Collet nut 4 Trigger
2Spindle 51/4”BSP(FemaleAirInlet)
3TriggerLock
1
2
345

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the travel plug from the
bottom of the tool as shown.
2. Pour 2-3 drops of CLARKE airline oil
into the air inlet. This should be
done regardless of whether or not
a lubricated air supply is to be
used.
3. Connect a suitable hose to the
tool as shown.
• Use the adapter supplied if
required.
4. Connect the other end of the hose
to the compressor.
You can fit a whip hose with a quick fit
coupling if required (available from
your Clarke dealer.)
COLLETS
Two collets of different sizes are provided (1/8” and 1/4”). Select whichever fits
the shank of the stone you have chosen to use.
If you need to change the collet,
follow instructions below.
1. Hold motor spindle from turning
with spanners supplied.
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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2. Remove collet nut and withdraw
collet.
3. Install new collet and re-fit collet
nut, (finger-tight only).
FITTING THE GRINDING POINT OR STONE
1. Loosen collet nut using the
spanners supplied.
2. Insert appropriate die grinding
point or stone.
IMPORTANT: You MUST have at least
half of the length of the spindle inside
the collet before use.
3. Tighten the collet using spanners
supplied
IMPORTANT: Never use chipped or cracked points or stones, always inspect
before fitting.
USING THE DIE GRINDER
1. Slide and hold the safety lever
forward (1) and depress throttle
lever (2).
• Wait until the die grinder is
running at full speed.
2. Cautiously offer stone to
workpiece.
• DO NOT APPLY EXCESS FORCE,
too much pressure could cause
stone to shatter resulting in personal injury.
3. When finished grinding, allow the tool to stop completely before putting it
down.