Clarke X-PRO CAT208 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1119 - ISS 1
3 IN 1 COMBINATION AIRTOOL KIT
MODEL NO: CAT208
PART NO: 3120525

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INTRODUCTION
Thank you for purchasing this CLARKE 3 in 1 Combination 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.
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.

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SPECIFICATIONS
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 CAT208
Dimensions (L x W x H) 198 mm (right angle grinder)
201 mm (die grinder)
266 mm (ratchet wrench)
x 72 mm x 43 mm
Weight 2.4 kg (complete)
Air Inlet Size 1/4”BSP (female)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4 cfm (average)
Speed settings Variable speed trigger
Die Grinder
Max No Load Speed
Collet size
Weight
18000 rpm @ 90psi
1/4“(6 mm)
0.795 kg
Right angle die grinder
Max No Load Speed
Collet size
Weight
15000 rpm @ 90psi
1/4”(6 mm)
0.915 kg
Ratchet wrench
Max No Load Speed
Reverse action
Maximum torques
Drive size
Weight
180 rpm @ 90psi
F/R knob
60 ft/lb (85 Nm)
3/8”
1.4 kg
Sound Pressure Level (LpA dB) 86 dB(A) (all tools)
Sound Power Level (LwA dB) 99 dB(A) (all tools)
Vibration Levels 3.95 m/s2(uncertainty factor 1.5 m/s2)

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GENERAL SAFETY RULES
THE 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 and visitors away - Do not let children handle the air
tool.
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 the air tool
when you are tired or under the influence of alcohol, drugs or medication.
2. ALWAYS wear eye protectors when using the air tool - Eye protectors must
provide protection from flying particles from the front and the side.
3. ALWAYS wear ear protectors when using the air tool.
4. DO NOT overreach - Keep proper footing and balance at all times.
5. DO NOT use oxygen, CO2, combustible gases or any type of bottled gas as
a source of power for the air tool.
6. DO NOT connect the air supply hose with your finger on the trigger.
7. DO NOT exceed the maximum pressure for the air tool of 90 psi / 6.2 bar.
8. ALWAYS check hoses for leaks or worn condition before use, and ensure
that all connections are secure.
9. DO NOT use the air tool for any other purpose than that described in this
manual.
10. ALWAYS keep the air hose away from heat, oil and sharp edges.
11. DO NOT fit the air tool to a stand or clamping device that may damage it.
12. DO NOT carry out any alterations or modifications to the air tool.
13. ALWAYS disconnect from the air supply when:
• Performing any maintenance.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• The air tool is not in use.
• The air tool will be left unattended.
• Moving to another work area.
14. DO NOT use the air tool if it is defective or operating abnormally.
15. DO NOT damage the air tool by applying excessive force.
16. ALWAYS maintain the air tool with care. Keep it clean for the best and
safest performance.
17. Quick change couplings should not be located at the air tool. They add
weight and could fail due to vibration.
18. DO NOT force or misuse the air tool. It will do a better and safer job at the
rate for which it was designed.
19. These air tools vibrates with use. Vibration may be harmful to your hands or
arms. Stop using the air tool if discomfort, a tingling feeling or pain occurs.
Seek medical advice before resuming use.
20. DO NOT carry the air tool by the air supply hose.
21. DO NOT carry the air tool with your finger on the trigger.
22. When not in use, disconnect the air tool from the air supply and store in a
dry place out of the reach of children.

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OVERVIEW
When opening the blow moulded case for the first time, check that all the
items are present. Any damage or deficiency should be reported to your
CLARKE dealer immediately.
NO DESCRIPTION NO DESCRIPTION
A Right Angle Drive attachment D 4 x Collet Wrenches (11,14,17
&19 mm)
B Ratchet wrench attachment E 1/4” Male Connector
C Die grinder attachment
1 Grease nipple 3 Trigger
2 Quick release locking collar 4 Air Inlet
5 Quick connector

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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
and topped up with oil. SAE 10 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.
.
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 air tool must comply with the appropriate
European Community Safety Directives.
The air hose should be rated at least 150% of the maximum operating pressure
of the tool.
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 the air tool does not exceed 90 psi at the
air tool when running. Higher pressures and unclean air will shorten the life of
the air tool due to faster wear and is a possible safety hazard.

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BEFORE USE
CONNECTING THE AIRLINE
1. Remove the plastic blanking plug from the air inlet connection.
2. Pour 2-3 drops of 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. 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.
5. Connect a suitable hose as shown
or use the snap connector to
connect directly to the hose.
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.
• PTFE tape may be useful for
sealing threaded connections.
8. 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.
9. Your air tool is now ready for use.
FITTING THE ATTACHMENTS
This 3-in-1 tool combi tool features an interchangeable tool head with quick-
release coupling. Choose your tool attachment.
Select the required tool head assembly (A, B, or C on page 6) and offer to the
main housing. Align the hexagonal quick-connection adapter (5) to the inner
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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hexagonal socket and insert. Pull the quick release locking collar backward
with one hand.
Release the quick release collar to retain the tool head assembly (A, B, or C).
Check that the tool head assembly is securely locked in place
.
THE DIE GRINDERS
FITTING THE GRINDING STONE
IMPORTANT: Never use chipped or cracked grindstones.
1. Slip the shank of the chosen
grinding stone into the collet and
tighten the screw cap finger tight.
2. Place the smaller of the two
wrenches (11mm) over the collet
seat to stop the tool from rotating.
3. Use the larger wrench (17mm) to
fully tighten the collet and grip the
stone in position as shown.
4. 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.

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OPERATING THE DIE GRINDERS
1. Slide the throttle locking lever
forward while squeezing the
trigger against the tool body.
• Do not use excess pressure on
the grinding stone as this will
shorten its life.
2. Release the trigger to stop the
grinder.
• The stone will continue to rotate
for a short time after the trigger
has been released.
3. Always ensure the die grinder has stopped before putting it down.
THE RATCHET WRENCH
SETTING THE DIRECTION OF ROTATION
To select the direction of rotation turn
the direction control as follows.
• For loosening bolts/nuts, turn the
direction control clockwise to R
(Reverse) .
• For tightening bolts/nuts, turn
the direction control anti-
clockwise to F (Forward).
FITTING SOCKETS AND USING THE RATCHET WRENCH
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.
WARNING: ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING
BEFORE SETTING THE DIRECTION CONTROL.

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3. Squeeze the trigger against the
body of the air tool to start.
4. Release the trigger to stop the tool.
5. Always ensure the air 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 air tool gently and squeeze the trigger to
tighten with power.
9. Final tightening should be completed by hand, using a torque wrench if
needed.
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.
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.
When not in use, disconnect from air supply, clean the tools and store in a
safe, dry place. When storing, replace the blanking plug to the air inlet once
the airline is disconnected.
Avoid storing air tool s where the temperature is below 0oC.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
tool.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force
applied to the tool.
2. Return to CLARKE dealer
for repair.
3. 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. Regulator in closed
position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
cleanliness.
2. Adjust 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. 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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MAINTENANCE
DAILY
1. Before use, drain water from the air tank, air line and compressor.
2. If no airline lubricator or mini oiler is used, ensure that oil is applied to the air
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 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 air 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 inside the air
tool may also reduce its
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.
SERVICE AND REPAIR
1. If the tool runs erratically or becomes inefficient although the air supply is in
good order, it may be necessary to dismantle the air motor and replace
any worn or damaged parts. Such servicing and repair work should be
carried out by a qualified service technician.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE.

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GREASING
The right angle drive is fitted with a
grease nipple to provide a facility for
lubrication of the drive gears.
1. After extensive use, apply a shot
of general purpose grease using a
suitable grease gun.
PERFORMANCE
Please note that outside factors may
affect the operation and efficiency
of the air tool.
These include reduced compressor output, excessive drain on the airline,
moisture ingress, restrictions in the air-line such as the use of connectors of
incorrect size or poor condition which will reduce the air supply.
Your air tool has been designed to give long & trouble free service. If, however,
having followed the instructions in this booklet carefully, you encounter
problems, take the unit to your local CLARKE dealer.
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 CLARKE International
Service Department.
CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
SUITABLE GRINDING STONES INCLUDE:
CAT144 (10 piece grinding stone set) part no 3120158.

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PARTS LIST - RATCHET WRENCH
No Description No Description
1 Main Housing 31 Quick release collar
2 Trigger 32 Circlip
3 Lever 33 Bushing
4 Spring 34 Adapter axle
5 Roll pin 35 Adapter sleeve
6 Roll pin 36 Cushion
7 O-ring 37 Bearing
8 O-ring 38 Gear ring
9 Valve stem 39 Gear
10 Spring 40 Bolt
11 O-ring 41 Gear seat
12 Screw 42 Screw nut
13 Exhaust deflector 43 Bushing
14 Air inlet 44 Needle bearing
15 Seal ring 45 Eccentric shaft
16 Bearing 46 Bushing
17 Rear plate 47 Ratchet head
18 Steel ball 48 Ratchet yoke
19 Rotor 49 F/R knob
20 Rotor blade 50 Spring
21 Cylinder 51 Sleeve
22 Front plate 52 Flexible spacer
23 Grub screw 53 Anvil
24 Bearing 54 Bolt
25 Bushing 55 Ratchet pawl
26 Set seat 56 Spacer
27 Steel ball 57 Ring washer
28 O-ring 58 Spring
29 Set ring 59 Soft grip
30 Spring

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COMPONENT PARTS - RATCHET WRENCH

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COMPONENT PARTS - STRAIGHT DIE GRINDER
No Description No Description
1 Main Housing 22 Front plate
2 Trigger 23 Grub screw
3 Lever 24 Bearing
4 Spring 25 Bushing
5 Roll pin 26 Set seat
6 Roll pin 27 Steel ball
7 O-ring 28 O-ring
8O-ring 29Setring
9 Valve stem 30 Spring
10 Spring 31 Quick release collar
11 O-ring 32 Ring washer
12 Screw 33 Bushing
13 Exhaust deflector 34 Adapter axle
14 Air inlet 35 Adapter sleeve
15 Seal ring 36 Screw nut
16 Bearing 37 Collet holder
17 Rear plate 38 Collet
18 Steel ball 39 Collet jacket
19 Rotor 40 Soft grip
20 Rotor blade 41 Small wrench (14mm)
21 Cylinder 42 Large wrench (19mm)

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COMPONENT PARTS - STRAIGHT DIE GRINDER

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PARTS LIST - RIGHT ANGLE DIE GRINDER
No Description No Description
1 Main Housing 27 Steel ball
2 Trigger 28 O-ring
3 Lever 29 Set ring
4 Spring 30 Spring
5 Roll pin 31 Quick release collar
6 Roll pin 32 Ring washer
7 O-ring 33 Bushing
8 O-ring 34 Adapter axle
9 Valve stem 35 Adapter sleeve
10 Spring 36 Bearing
11 O-ring 37 Screw nut
12 Screw 38 Set ring
13 Exhaust deflector 39 Bearing
14 Air inlet 40 Gear
15 Seal ring 41 Right angle housing
16 Bearing 42 Grease nipple
17 Rear plate 43 Bearing
18 Steel ball 44 Gear
19 Rotor 45 Set ring
20 Rotor blade 46 Work spindle
21 Cylinder 47 Semicircular key
22 Front plate 48 Collet
23 Grub screw 49 Collet jacket
24 Bearing 50 Soft grip
25 Bushing 51 Small wrench (11 mm)
26 Set seat 52 Large wrench (17 mm)