Clarke Air CAT120 Installations- und Betriebshandbuch

OPERATING & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0420 - ISS 2

43-PC AIR TOOL KIT

MODEL NO: CAT120

PART NO: 3110876

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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 CAT120 Air Tool Kit should include the following:

AIR TOOLS IN THE KIT

1 x ½” Square Drive Impact Wrench

1 x Air Hammer

1 x Reversible Drill

1 x ¼” Die Grinder

1 x Dual Acting Sander

GENERAL ACCESSORIES

1 x Air Inlet Adaptor (¼”male)

1 x Oil Bottle

1 x Hex Key 4mm

FOR THE DRILL

1 x Chuck key

4 x 6.35 mm Hex shank screwdriver bits:

Sizes: 4 & 6 mm straight; Phillips Nos. 2 & 3

FOR THE DIE GRINDER

5 x Assorted grinding stones - 6 mm shank

5 x Assorted grinding stones - 3 mm shank

1 x Pair of spanners

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

FOR THE CHIPPING HAMMER

4 x Chisels with various profiles (10.2 mm locating shank - 125 mm length)

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: 9,10,11,13,14,17,19,22,24,27 mm

TECHNICAL SPECIFICATIONS

The 5 x air tools supplied in this CAT120 kit have a 1/4” BSP female threaded

connection for use with an maximum air supply pressure of 90 psi (6.2 bar).

IMPACT WRENCH

Air Consumption 8 cfm

Drive size 1/2” square

Max No Load Speed 7000 rpm @ 90psi

Max Torque 230 ft/lb

Sound Pressure Level (LpA dB) 84.4 dB(A)

Sound Power Level (LwA dB) 95.4 dB(A)

Vibration Levels 2.6 m/s2(uncertainty factor K= 0.72m/s2)

Dimensions (L x W x H) & Weight 220 x 75 x 180 mm Weight 2.2 kg

HAMMER/CHISEL

Air Consumption 3-16 cfm (84-452 l/min)

Max Blows per minute 4500

Vibration Levels 14.6 m/s2(uncertainty factor (K= 0.99m/s2)

Sound pressure level 84 dB LpA

Sound power level 95 dB LWA

Dimensions (L x W x H) & Weight 153 x 48 x 152 mm Weight = 1.1 kg

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

REVERSIBLE DRILL

Chuck Size 1.5 - 10 mm

Air Consumption 6 cfm

Max Speed 1800 rpm

Sound Pressure Level (LpA dB) 87 dB(A)

Sound Power Level (LwA dB) 98 dB(A)

Vibration Levels 1.2 m/s2 (K= 1.25 m/s2 )

Dimensions (L x W x H) & Weight 191 x 42 x 144 mm Weight 1.15 kg

DIE GRINDER

Air Consumption 4 cfm (1151 l/min)

Max Speed 22000 rpm

Sound Pressure Level (LpA dB) 83.5 dB(A)

Sound Power Level (LwA dB) 94.5 dB(A)

Vibration Levels 1.2 m/s2(K=0.35 m/s2)

Dimensions (L x W x H) & Weight 173 x 46 x 68 mm Weight 0.64 kg

DUAL-ACTING SANDER

Air Consumption @ 6.3 bar 2-16 cfm (56-452 l/min)

Pad size 150 mm

Sound Power Level 98.2 dB LWA

Sound Pressure Level 87.2 dBA

Vibration Level 2.5 m/s2

Uncertainty Factor (K) 1.25 m/s2

Dimensions (L x D x H) & Weight 223 x 73 x 123 mm Weight = 1.81 kg

Max Speed 10,000 rpm

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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.

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.

CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN

PERSONAL INJURY AND/OR DAMAGE TO PROPERTY.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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.

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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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.

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.

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU

ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF

COMPRESSORS AND COMPRESSED AIR SYSTEMS.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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.

CONNECTING THE TOOLS TO THE AIR LINE

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 to prolong the life

of any air tool.

4. Connect a suitable hose as shown

or use the 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.

Your air tool is now ready for use.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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 5

¼” female inlet adaptor

2 Forward/reverse button 6 Handle

3 Trigger 7 Oil port

4SpeedControl

WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH

SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR

USE WITH IMPACT TOOLS.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

ADJUSTING THE DIRECTION AND SPEED

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 he impact wrench should be operated in the reverse (R)

direction.

NOTE: Where the torque setting is critical, the final tightening of nuts or

bolts, must be by hand using a correctly calibrated torque

wrench.

ADJUSTING THE POWER

To adjust the power, set the air regulator to one of the 4 settings available.

1 (Low) - 4 (High)

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.

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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