Clarke CAT101 Manual

1/2” IMPACT WRENCH
1/2” IMPACT WRENCH
MODEL No: CAT101
Part No: 3110857
OPERATION & MAINTENANCE
INSTRUCTIONS
0707

2
SPECIFICATIONS
Drive Size ................................................... 1/2” Square
Max Torque ............................................... 260 ft/lb (352 Nm)
Air Inlet ....................................................... 1/4” BSP
Ave. Air Consumption .............................. 4.5 cfm
Air Pressure Max ....................................... 6.2 bar
Noise Level ................................................ 94dB A
Vibration Level ......................................... 10.4m/s2
Net Weight ................................................ 2.23 kg
Dimensions LxWxH .................................... 220 x 70 x 200
Part No ....................................................... 3110857
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. Always consult the machine’s data plate
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of 12 months
from the date of purchase. Please keep your receipt 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.
IN THE BOX
1 X 1/2” Impact wrench with 2” Anvil
1 X Instruction Book

3
SAFETY PRECAUTIONS
IMPORTANT
FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY,
AND/OR DAMAGE TO PROPERTY.
WORK ENVIRONMENT
• Keep the work area clean and tidy.
• Dress appropriately - Do not wear loose clothing or jewellery. Tie long hair out of
the way.
• Keep children and visitors away - Do not let children handle the impact wrench.
Make sure that any other persons in the work area are dressed suitably and are
wearing eye and ear protectors.
• Do not operate the impact wrench where there are flammable liquids or gases.
• Keep the air supply hose away from heat, oil and sharp edges.
• Do not fit the impact wrench to any stand or clamping device that may damage
the tool.
USE
• Stay alert and use common sense - Do not operate the impact wrench when you
are tired or under the influence of alcohol, drugs or medication.
• Always wear eye protectors when using the impact wrench - Eye protectors must
provide protection from flying particles from the front and the side.
• Always wear ear protectors when using the impact wrench.
• Do not overreach - Keep proper footing and balance at all times.
• Never use any type of bottled gas as a source of power for the impact wrench.
• Do not connect the air supply hose with your finger on the trigger of the impact
wrench.
• Do not exceed the maximum pressure for the impact wrench: 90 psi / 6 bar.
• Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
• Do not use the impact wrench for any other purpose than that described in this
book.
• Do not carry out any alterations or modifications to the impact wrench.

4
SAFETY PRECAUTIONS
• Always disconnect from the air supply when:
a) Performing any maintenance
b) The impact wrench is not in use.
c) The impact wrench will be left unattended.
d) Moving to another work area.
e) Passing the impact wrench to another person.
• Never use the impact wrench if it is defective or operating abnormally.
• The impact wrench should be serviced at regular intervals by qualified service
personnel.
• Avoid damaging the impact wrench for example by applying excessive force of
any kind.
• ALWAYS maintain the tool with care. Keep it clean for best and safest
performance.
• Quick change couplings should not be located at the tool. They add weight and
could fail due to vibration.
• DO NOT force or misuse the tool. It will do a better and safer job at the rate for
which it was designed.
• DO NOT remove any labels. Damaged labels should be replaced.
• 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.
• NEVER use standard sockets. These may shatter with serious consequences. Use
ONLY Impact sockets.
TRANSPORTATION
• Never carry the impact wrench by the air supply hose.
• Never carry the impact wrench with your finger on the trigger.
STORAGE
• When not in use the impact wrench must be disconnected from the air supply
and stored in a dry place out of the reach of children (preferably in a locked
cabinet).
• Avoid storing the impact wrench in environments where the temperature is below
0oC.

5
PARTS
Trigger
Air Regulator
Direction Selector
Anvil
AIR SUPPLY
WARNING!
COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU ARE THOROUGHLY
FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF COMPRESSORS AND
COMPRESSED AIR SUPPLY.
• Use only clean, dry, regulated compressed air as a power source for the impact
wrench.
• Air compressors used with the impact wrench 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 impact wrench.
• Never exceed the maximum operating pressure for the impact wrench.
AIR HOSE
• The air hose must be rated at least 150% of the maximum operating pressure of
the tool.
Air Inlet

6
RECOMMENDED AIR SUPPLY CONNECTION
ASSEMBLY
NOTE: ensure the compressor is turned off.
1. Connect a suitable hose to the impact
wrench using a ¼” hose adapter.
2. Connect the other end of the hose to the
compressor.
3. 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 THOROUGHLY
FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF COMPRESSORS AND
COMPRESSED AIR SUPPLY.

7
OPERATING INSTRUCTIONS
WARNING!
WAIT UNTIL THE ANVIL HAS STOPPED ROTATING BEFORE OPERATING THE
DIRECTION CONTROL SWITCH.
USING THE DIRECTIONAL CONTROL BUTTON
The direction control 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.
Direction control button in
forward position Direction control button in reverse position
FITTING THE IMPACT SOCKET
1 Select the impact socket you require
WARNING!
NEVER use standard sockets. These may
shatter with serious consequences. Use
ONLY Impact sockets.
2 Push the inpact socket onto the anvil
as shown.

8
OPERATING INSTRUCTIONS
ADJUSTING THE POWER
To adjust the power, set the
air regulator to one of the 4
settings avalaible.
1 (Low) - 4 (High).
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
Squeeze
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 to
stop the impact wrench.
Air Regulator

9
MAINTENANCE
WARNING! Make sure that the impact wrench is disconnected from the air supply before
starting any cleaning, or maintenance procedures.
Daily
• Drain water from air tank, air line and compressor.
• Pour a few drops of CLARKE Air Line Oil, into the air inlet. This should be carried out
regardless of whether or not an air line lubricator is used. If an Air line lubricator is not
used, this procedure should be repeated after every two to three hours of use.
Weekly
• Check the air inlet screen filter and clean if necessary.
• Remove the grub screw and insert a few drops of oil into the oil port on the side of
the impact wrench.
CLEANING
• Keep the body of the impact wrench clean and free from debris, Grit or gum
deposits in the tool may reduce efficiency.
SERVICE AND REPAIR
• All servicing and repair must be carried out by qualified service technicians.
NOTES
Please note that factors other than the tool may effect its operation and efficiency such
as reduced compressor output, excessive drain on the airline, moisture or restrictions in
the line, or the use of connectors of improper size or poor condition which will reduce air
supply.
**Clarke Air Line Oil is available from your CLARKE dealer part no. 3050825.
We declare that these products comply to the following standards/directives
• 98/37/EC
Model No: CAT101
Serial or Batch number: See product data plate
signature:
D. Kemp
ENGINEERING MANAGER
DECLARATION OF CONFORMITY

10
PARTS DIAGRAM
PARTS LIST
Index Part Description
No. No.
1 KL504W01 Housing
2 KL504W02 Valve Bushing
3 KL504W03 Reverse Valve
4 KL504W04 Trigger
5 KLSP007 Pin
6 KL504W06 Valve Stem
7 KL504W07 Air Inlet
8 KL504W08 Ball Seat
9 KL506AW43 Spring
10 KLAA065 Steel Ball
11 KL504W11 Cover
12 KL504W12 Air Regulator
13 KLSO016 O-Ring
14 KL504W14 Spring
16 KLSH028 Screw
17 KL504W171 Bushing
18 KL504W183 Anvil
19 KL504W19 Hammer Cage
20 KL504W20 Hammer Pin
21 KL504W21 Hammer Dog
22 KL504W22 Drive Cam
23 KLSP008 Pin
24 KL504W24 Cylinder
25 KL504W25 Rotor
26 KL504W26 Rotor Blade
27 KL504W27 Rear End Plate
28 KLCA6001 Ball Bearing
29 KL504W29 Front End Plate
30 KLSP006 Pin
31 KL504W31 Spring
32 KL504W32 Pin
33 KL504W33 Gasket
34 KL504W34 Rear Cover
35 KLSH0031 Screw& Spring Washer
36 KL504W37 Front Rubber
37 KL504W38 Exhaust Deflector
38 KLSH041 Screw
39 KLSH027 Screw
40 KL504W41 Anvil Collar
41 KLSO009 O-Ring
42 KL504W43 Rubber
43 KLSH045 Screw
44 KL504W45 Oil Seal
Index Part Description
No. No.

11
Employers are advised to refer to the HSE publication “Guide for Employers”.
All hand held power tools vibrate to some extent, and this vibration is transmitted to the
operator via the handle, or hand used to steady the tool. Vibration from about 2 to 1500
herz is potentially damaging and is most hazardous in the range from about 5 to 20 herz.
Operators who are regularly exposed to vibration may suffer from Hand Arm Vibration
Syndrome (HAVS), which includes ‘dead hand’, ‘dead finger’, and ‘white finger’. These
are painful conditions and are widespread in industries where vibrating tools are used.
The health risk depends upon the vibration level and the length of time of exposure to
it……in effect, a daily vibration dose.
Tools are tested using specialised equipment, to approximate the vibration level generated
under normal, acceptable operating conditions for the tool in question. For example, a
grinder used at 45° on mild steel plate, or a sander on softwood in a horizontal plane etc.
These tests produce a value‘ a’ , expressed in metres per second per second, which
represents the average vibration level of all tests taken, in three axes where necessary,
and a second figure ‘K’, which represents the uncertainty factor, i.e. a value in excess of
‘a’, to which the tool could vibrate under normal conditions. These values appear in the
declaration on page 2.
HAND-ARM VIBRATION
You will note that a third value is given in the specification - the highest measured reading
in a single plane. This is the maximum level of vibration measured during testing in one of
the axes, and this should also be taken into account when making a risk assessment.
‘ a ’ values in excess of 2.5 m/s2 are considered hazardous when used for prolonged periods.
A tool with a vibration value of 2.8 m/s2may be used for up to 8 hours (cumulative) per
day, whereas a tool with a value of 11.2 m/s2may be used for ½ hour per day only.
The graph below shows the vibration value against the maximum time the respective
tool may be used, per day.
The uncertainty factor should
also be taken into account
when assessing a risk. The two
figures ‘ a ’ and ‘ K ’may be
added together and the
resulant value used to assess the
risk.
It should be noted that if a tool
is used under abnormal, or
unusual conditions, then the
vibration level could possibly
increase significantly. Users must
always take this into account
and make their own risk
assessment, using the graph as
a reference.
Some tools with a high vibration value, such as impact wrenches, are generally used for
a few seconds at a time, therefore the cumulative time may only be in the order of a few
minutes per day. Nevertheless, the cumulative effect, particularly when added to that
of other hand held power tools that may be used, must always be taken into account
when the total daily dose rate is determined.