Clarke CAT103 Instruction Manual

1/2”HEAVY DUTY IMPACT WRENCH
1/2”HEAVY DUTY IMPACT WRENCH
MODEL No: CAT103
Part No: 3110859
OPERATION & MAINTENANCE
INSTRUCTIONS
0707

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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 ........................................................400 ft/lb (542 Nm)
Air Inlet ................................................................1/4” BSP
Ave. Air Consumption ......................................4 cfm
Air Pressure Max ................................................6.2 bar (90psi)
Noise Level .........................................................91 dB A
Vibration Level ..................................................1.2m/s2
Net Weight .........................................................2.78 kg
Dimensions LxWxH.............................................245 x 73 x 186
Part No................................................................3110859
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: 90 psi / 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
Direction
Selector +
Air Regulator
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 5 settings
avalaible.
1 3300 rpm
2 6070 rpm
3 7216 rpm
4 7740 rpm
5 8000 rpm
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.
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: CAT103
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.
01 KLCAT10301 Motor Housing
02 KLCAT10302 Throttle Valve
03 KLCAT10303 Throttle Valve Face
04 KLCAT10304 Throttle Valve Spring
05 KLCAT10305 Throttle Valve Stem
06 KLCAT10306 Air Strainer Assembly
08 KLCAT10307 Trigger
09 KLCAT10308 Trigger Pin
10 KLCAT10309 Reverse Valve Bushing
11 KLCAT10310 Reverse Valve Bushing
Seal
12 KLCAT10311 Reverse Valve
13 KLCAT10312 Reverse Valve Detent
Ball
14 KLCAT10313 Reverse Valve Detent
Spring
15 KLCAT10314 Reverse Valve Knob
16 KLCAT10315 Reverse Valve Knob
Screw
17 KLCAT10316 Grease Fitting
22 KLCAT10317 Rotor
23 KLCAT10318 Rear Rotor Bearing
24 KLCAT10319 Front Rotor Bearing
25 KLCAT10320 Rear Rotor Bearing
Retainer
26 KLCAT10321 Cylinder
27 KLCAT10322 Cylinder Dowel
29 KLCAT10323 Rotor Blade
30 KLCAT10324 Front End Plate
31 KLCAT10325 Rear End Plate
32 KLCAT10326 End Plate Gasket
33 KLCAT10327 Motor Clamp Washer
34 KLCAT10328 Hammer Frame
35 KLCAT10329 Hammer Pin
36 KLCAT10330 Hammer Frame Rear
Washer
37 KLCAT10331 Hammer
38 KLCAT10332 Hammer Case
38A KLCAT10333 Hammer Case Pilot
39 KLCAT10334 Hammer Case Gasket
40 KLCAT10335 Hammer Case Bushing
41 KLCAT10336 Hammer Case Cap
Screw
43A KLCAT10337 Standard Anvil
43B KLCAT10338 853-2 2"Extended Anvil
44 KLCAT10339 Socket Retainer
45 KLCAT10340 Retainer O-Ring
Index Part Description
No. No.

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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 aretestedusing specialised equipment, toapproximate 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 of2.5 m/s2 are considered hazardous whenused 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
increasesignificantly. 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.