Clarke X-Pro CAT202 Operating & Maintenance Instructions Download

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OPERATING & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC1219 ISS 1

44-PC AIR TOOL KIT

MODEL NO: CAT202

PART NO: 3120519

Summary of Contents for X-Pro CAT202

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

Page 2: ...e 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 Reversible Ratchet Wrench 1 x Air Hammer 1 x Square Drive Impact Wrench 1 x Die Grinder 1 x Blow...

Page 3: ...ted 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 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 s...

Page 4: ... 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 P...

Page 5: ...perated 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 Di...

Page 6: ...IR 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...

Page 7: ...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 ...

Page 8: ... 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 th...

Page 9: ... 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 ...

Page 10: ...y 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 ...

Page 11: ...he 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 co...

Page 12: ...ket you require which must be in good condition and fit the tool exactly 2 Push the socket onto the square drive shaft as shown 1 1 2 Square Drive 4 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 ...

Page 13: ...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 loosene...

Page 14: ...ghten 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 TH...

Page 15: ...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 2 Trigger 3 Air Inlet 4 Male inlet adaptor 5 Chisels flat pointed ...

Page 16: ... 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 DIS...

Page 17: ...he 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 3 Trigger WARNING ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING BEFORE SETTING THE DIRECT...

Page 18: ...eak 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 wi...

Page 19: ...quire 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 ...

Page 20: ...let 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 lockin...

Page 21: ...efore 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 CLARKE airline 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 Th...

Page 22: ...e hammer mechanism and applying a small amount of good quality bearing grease This may be better left to your CLARKE dealer STORAGE If the tool is to be stored or is idle for longer than 24 hours run a few drops of air line oil into the air inlet and depress the trigger in order to lubricate the internal parts When not in use the tool should be disconnected from the air supply and stored in a dry ...

Page 23: ...e 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 ...

Page 24: ... Grease cap 4 Pin 25 Gasket 5 E ring 26 O ring 6 Bearing 27 Switch 7 Rear plate 28 Spring 8 Cylinder 29 Steel ball 9 Bolt 30 O ring 10 Rotor 31 Rear cover 11 Spring 32 Set screw 12 Rotor blade 33 Exhaust deflector 13 Front plate 34 Cushion 14 Bearing 35 Bolt 15 Hammer cage 36 Circlip 16 Hammer dog 37 Spacer 17 Hammer pin 38 Oil seal 18 Anvil 39 Tilt valve 19 O ring 40 Spring 20 Retainer bolt 41 O ...

Page 25: ...25 Parts Service 020 8988 7400 E mail Parts clarkeinternational com or Service clarkeinternational com PARTS DIAGRAM IMPACT WRENCH ...

Page 26: ...ernational com PARTS LIST DIAGRAM AIR CHISEL No Description No Description 1 Main housing 11 O ring 2 Valve seat 12 Valve stem 3 Valve plate 13 Trigger 4 End cap 14 Set pin 5 Piston 15 Air inlet 6 Cylinder 16 Pointed chisel 7 Retainer spring 17 Flat chisel 8 O ring 9 Valve sleeve 10 Spring ...

Page 27: ...27 Parts Service 020 8988 7400 E mail Parts clarkeinternational com or Service clarkeinternational com COMPONENT PARTS DIAGRAM RATCHET WRENCH ...

Page 28: ...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 cap 35 Ratchet yoke 12 Nipple 36 Forward reverse knob 13 Exhaust deflector 37 Sleeve 14 Air inlet 38 Spring 15 Decorative 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 ...

Page 29: ...ARKE catalogue CLARKE Air Line Oil part no 3050825 is available from your CLARKE dealer No Description No Description 1 Main Housing 21 O ring 2 Housing liner 22 Screw 3 Bushing 23 Bearing 4 O ring 24 Rear plate 5 Trigger 25 Set pin 6 Lever 26 Rotor 7 Spring 27 Rotor blade 8 Roll pin 28 Cylinder 9 Trigger pin 29 Bushing 10 Air inlet 30 Front plate 11 Spring 31 Steel ball 12 Pin 32 Bearing 13 O rin...

Page 30: ...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 effec...

Page 31: ...31 Parts Service 020 8988 7400 E mail Parts clarkeinternational com or Service clarkeinternational com DECLARATION OF CONFORMITY ...

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