Clarke CAT102 Instruction Manual

1/2”HEAVY DUTY IMPACT WRENCH
1/2”HEAVY DUTY IMPACT WRENCH
MODEL No: CAT102
Part No: 3110858
OPERATION & MAINTENANCE
INSTRUCTIONS
0507

2
Thank you for purchasing this CLARKE Heavy Duty Impact Wrench, designed for heavy
automotive and industrial use, and incorporating adjustable power settings, forward and
reverse action and a twin hammer impact mechanism.
Before using the wrench, please read this leaflet 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 it giving long and satisfactory service.
SPECIFICATIONS
Drive Size ............................................................1/2” Square
Max Torque ........................................................380 ft/lb (516 Nm)
Air Inlet ................................................................1/4” BSP
Ave. Air Consumption ......................................4.2 cfm
Air Pressure Max ................................................6.2 bar
Noise Level .........................................................88.2 dB A
Vibration Level ..................................................2.5m/s2
Net Weight .........................................................2.82 kg
Dimensions LxWxH.............................................245 x 72 x 215
Part No................................................................3110858
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” Heavy duty impact wrench with 2” anvil
1 X Instruction book

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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: 6.2 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.

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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.

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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

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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.

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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.

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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

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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: CAT102
Serial or Batch number: See product data plate
signature:
D. Kemp
ENGINEERING MANAGER
DECLARATION OF CONFORMITY

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PARTS DIAGRAM
PARTS LIST
Index Part Description
No. No.
1 KL004202 Oil Seal
2 KL000107 Cap Screw
3 KL001802 Spring Washer
4 KL290002D Hammer Case
5 KL290023B Front Gasket
6 KL302010 Anvil Bushing
7 KL302033 Spacer
8 KL004103 O-Ring
9 KL250033 Anvil Collar
10 KL302011NB4 2" Anvil
11 KL300018 Spring
12 KL300016 Hammer Pin
13 KL302013 Cam
14 KL003807 Steel Ball
15 KL302014 Cam Foundation
16 KL302012 Hammer Cage
17 KL290019 Reverse Valve
18 KL290020 Valve Sleeve
19 KL290028 Trigger
20 KL003303 Spring Pin
21 KL000614 Set Screw
22 KL290001F Motor Housing
23 KL004122 O-Ring
24 KL290022B Regulator
25 KL003302 Spring Pin
26 KL004101 O-Ring
27 KL290025 Valve Stem
28 KL250034 Bushing
29 KL003801 Steel Ball
30 KL250023 Spring
31 KL250024A Air Inlet (1/4"PF)
32 KL250029 Pin
33 KL250028 Spring
34 KL000609 Set Screw
35 KL002306 Bear Balling
36 KL004201 Oil Seal
37 KL004120 O-Ring
38 KL290005 Front End Plate
39 KL003304 Spring Pin
40 KL290006F Cylinder
41 KL003308 Spring Pin
42 KL290007F Rotor
43 KL290008 Rotor Blade
44 KL290009F Rear End Plate
45 KL002305 Ball Bearing
46 KL290021B Rear Gasket
47 KL290003 Rear Cover
48 KL000101 Cap Screw
49 KL250035 Protecting Rubber
50 KL271023 Spring
51 KL003802 Steel Ball
Index Part Description
No. No.