Clarke CAT154 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0317
1”AIR IMPACT WRENCH
MODEL NO: CAT154
PART NO: 3120168

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INTRODUCTION
Thank you for purchasing this CLARKE Impact Wrench. Please read all of the
safety and operating instructions carefully before using this product. 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.
SPECIFICATION
Dimensions (L x W x H) 630 x 230 x 200 mm
Weight(s) 17.2 kg
Drive size 1” square
Min. Hose Size (ID) 1/2” BSP (13mm)
Air Inlet Size 1/2”BSP female
Max Operating Pressure 113-143 psi (8-10 kg/cm2)
Air Consumption Max 55 cfm /average 10 cfm
Max Torque 3800 Nm (+/-10%)
Max No Load Speed 3500 rpm @ 90 psi
Speed Settings & RPM
Forward/Reverse 1 2200 (+/-10%)
Forward/Reverse 2 3200 (+/-10%)
Forward/Reverse 3 3500 (+/-10%)
Sound Pressure Level (LpA dB) 91 dB(A)
Sound Power Level (LwA dB) 102 dB(A)
Vibration Level 14.9 m/s2 (uncertainty factor K= 2.3m/s2)

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GENERAL SAFETY RULES
WORK ENVIRONMENT
1. Keep the work area clean and tidy.
2. Dress appropriately - Do not wear loose clothing or jewellery. Tie long hair
out of the way.
3. Keep children and visitors away - Do not let children handle the tool.
4. Do not operate the tool where there are flammable liquids or gases.
USE OF COMPRESSED AIR TOOLS
1. Stay alert and use common sense - do not operate the tool when you are
tired or under the influence of alcohol, drugs or medication.
2. Always wear eye protectors when using the tool. Eye protectors must
provide protection from flying particles 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. Never use oxygen, CO2, combustible gases or 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 tool of 90 psi / 6.2 bar.
7. Keep the air supply hose away from heat, oil and sharp edges.
8. Do not fit the tool to any stand or clamping device that may damage it.
9. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
10. Do not use the tool for any purpose than that described in this manual.
11. Do not carry out any alterations or modifications to the tool.
12. Always disconnect from the air supply when:
• Performing any maintenance.
• The tool is not in use.
• The tool will be left unattended.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• Moving to another work area.
• Passing the tool to another person.
13. Never use the tool if it is defective or operating abnormally.
14. This tool should be serviced at regular intervals by qualified personnel.
15. Avoid damaging the tool by applying excessive force.
16. Always maintain the tool with care. Keep it clean for the best and safest
performance.
17. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
18. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
19. Do not remove any labels. Damaged labels should be replaced.
20. 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.
IMPACT WRENCH SAFETY INSTRUCTIONS
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 wheel nuts or engine parts 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 over tightening.
5. Always ensure that the socket is correctly installed before switching on.
6. Only use sockets which are specified for impact wrench use.
7. Due to the possible presence of asbestos dust from vehicle brake linings,
always wear suitable respiratory protection.
9. Always disconnect from the air supply when changing sockets or when the
wrench is not required for immediate use to avoid accidental starting.
10. Always store this product in a dry, secure place out of reach of children or
untrained users.
11. Always use both hands to control the impact wrench.
12. Always ensure the wrench has stopped before putting it down after use.

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TRANSPORT & STORAGE
1. Never carry the wrench by the air hose.
2. Never carry the wrench with your finger on the trigger.
3. When not in use the wrench should be disconnected from the air supply
and stored in a dry place out of reach of children.
4. Avoid storing the wrench where the temperature is below 0oC.
SAFETY SYMBOLS
The following safety symbols are to be found on the tool.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
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 effect your statutory rights.
Read this instruction
booklet carefully
before use.
Wear ear protection.
Wear eye protection.

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COMPRESSED AIR REQUIREMENTS
• 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.
• 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 tool.
• A typical air line layout is shown above. If an automatic in-line filter/
regulator is used, it will keep the tool in good condition, but should
be regularly checked and topped up with oil. clarke airline oil should
be used, and the lubricator adjusted to approx 2 drops per minute.
• For optimum performance a minimum 13mm ID air hose is used.
• Never exceed the maximum operating pressure for the tool. It is
recommended that air pressure to this tool does not exceed 90 psi
at the tool when running. Higher pressures and dirty air will shorten
the life of the tool due to faster wear and is a possible safety hazard.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. The side handle is supplied loose
and must be fitted to the impact
wrench using the bolts provided.
2. Remove the plastic blanking plug from the air inlet connection.
3. Pour 2-3 drops of Clarke airline oil
into the oil filling port shown. This
should be done regardless of
whether or not a lubricated air
supply is to be used.
4. Connect a suitable hose to the
wrench.
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.
• PTFE tape may be useful for sealing threaded connections.
7. Your air tool 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 FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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OPERATION
FITTING AN 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.
THE FORWARD/REVERSE/SPEED CONTROL
Forward/Reverse rotation is selected by twisting the combined Forward/
Reverse knob/speed regulator in the direction shown by the arrow(s) on the
the wrench.
1. For normal tightening, the wrench
should be operated in the forward
(F) direction at position 1, 2 or 3.
2. For loosening, the wrench will be
operated in the reverse (R)
direction.
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR
USE WITH IMPACT TOOLS.
CAUTION: ALWAYS TAKE CARE TO USE THE CORRECT SIZE SOCKET FOR
BOLTS AND NUTS. AN INCORRECT SOCKET WILL CAUSE DAMAGE TO THE
BOLT OR NUT.
WARNING: WAIT UNTIL THE ANVIL HAS STOPPED ROTATING BEFORE
OPERATING THE FORWARD/REVERSE CONTROL.

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OPERATING THE IMPACT WRENCH
1. Locate the socket over the nut to
be tightened or loosened.
2. Squeeze the trigger to start the
wrench.
3. Release the trigger switch to stop
the wrench.
• The anvil will continue to rotate
very briefly after the trigger has
been released.
ADJUSTING THE SPEED
1. To adjust the speed, set the tool to
one of the 3 settings available.
(Setting 1- Low, 3 - High)
• These numbers are only for
reference and do not denote a
specific amount of power.
For maximum power when removing
stubborn nuts, turn the impact wrench
to its highest setting.
IMPORTANT: Where the torque setting is critical, the final tightening of nuts or
bolts, must be by hand using a properly calibrated torque wrench.
LOOSENING A WHEEL NUT
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 will be impacted repeatedly until it is loosened. IMPORTANT! Release
the trigger as soon as the nut begins to loosen.
3. Jack up the vehicle according to the vehicles handbook so that the wheel
is clear of the ground, then proceed to fully undo the wheel nuts.
4. Soak rusted nuts in penetrating oil, and break rust seal before twisting off
with the wrench.
WARNING: ENSURE THAT THE CORRECT SOCKET IS BEING USED FOR THE
NUTS ON YOUR PARTICULAR VEHICLE. AN INCORRECT SOCKET SIZE IS
LIKELY TO DAMAGE THE HEADS OF THE BOLTS/NUTS.

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TIGHTENING A NUT
1. Start the nut by hand, ensuring it is not cross threaded, then with the
appropriate socket installed on the wrench, place it on the nut.
2. With the FORWARD/NEUTRAL/REVERSE selector in the clockwise (FORWARD)
running position, and holding the wrench firmly in BOTH HANDS, pull the
trigger.
3. Run each nut up in turn until it is ‘nipped’ up only - do not tighten. When all
nuts are nipped up, tighten 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 meets the
vehicle manufacturer’s recommendations.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released.
2. Refer to the compressor instruction manual for the procedure to shut down
and vent the compressed air.
3. Once the pressure has been released, disconnect the air supply hose from
the wrench.
MAINTENANCE
DAILY
1. Before use, drain water from the airline filter and compressor.
2. If no line lubricator is used, ensure that oil is applied to the tool on a daily
basis through the air inlet connection.
3. For lubricating the air motor, an air line lubricator should be used,
(containing Clarke Air Line Oil). If this is not possible, run a few drops of 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. Then operate the tool.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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4. Pour a few drops of Clarke air-line oil, into the tool air inlet. This should be
carried out regardless of whether or not an in-line oiler is used. If an in-line
oiler is not used, this procedure should be repeated after every two to
three hours of use, or at the start of the working day.
5. Keep the body of the tool clean and free from debris.
CLEANING
1. Grit or gum deposits in the tool
may reduce efficiency and cause
it to run erratically. This condition
can be corrected by cleaning the
air strainer and flushing out the
tool with gum solvent oil.
2. Failing this, the tool should be
disassembled, thoroughly
cleaned, dried and reassembled.
3. The tool may be dismantled by
unfastening the bolts and
removing the rear cover prior to
replacing any worn or damaged
parts. You may prefer to take the
tool to your Clarke dealer if
internal maintenance is required.
4. While is a dismantled state, it may
be desirable to grease the
hammer mechanism and
applying a small amount of good
quality bearing grease.
• This may be better left to your Clarke dealer.
PERFORMANCE
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 air-line, or the use of connectors of improper size
or poor condition which will reduce air supply.
**Clarke Air Line Oil (part no. 3050825) is available from your Clarke dealer.
• Your air tool has been designed to give long & trouble free service.
If, however, having followed the instructions in this booklet carefully,
you encounter problems, take the unit to your local Clarke dealer.
• Any major servicing and repairs should be carried out by your local
Clarke dealer or a qualified service technician.

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TROUBLESHOOTING
STORAGE
If the tool is to be stored, or is idle for longer than 24 hours, run a few drops of
Clarke air line oil into the air inlet, and run the tool for 5 seconds in order to
lubricate the internal parts. Store the tool safely in its box in a dry, secure
environment.
When storing, ensure the blanking plug is replaced on the airline connector
once the airline has been disconnected.
**Clarke Airline Oil is available from your Clarke dealer: Part no 3050825.
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Air motor parts worn.
2. Worn or sticking
mechanism due to
lack of lubricant.
1. Return to Clarke dealer
for repair.
2. 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. Air motor parts
jammed with gum/
dirt.
2. Air-line regulator in
closed position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
blockage. Drip a few
drops of air tool lubricat-
ing oil into air inlet.
2. Adjust in-line regulator to
open position.
3. Operate tool in short
bursts.
Tool will not run. Air flows
freely from exhaust.
1. Air motor vanes stuck
due to buildup of
foreign material.
1. Disconnect air supply
and rotate tool assembly
manually.
2. Try operating tool in
short bursts.
3. Tap motor housing gently
with a rubber mallet.
4. Drip a few drops of air
tool lubricating oil into air
inlet to soak moving
parts.
Tool will not shut off. 1. Throttle O-rings
damaged or ill-fitting
in seat.
1. Return to Clarke dealer
for repair.

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PARTS LIST
ACCESSORIES
A wide range of accessories is available including filter/regulators, lubricators,
high-pressure hoses (5 to 50 metres) etc.
Contact your Clarke dealer for further information or the Clarke International
Service Department.
No Description No Description
1 Socket Head Bolt 25 Cylinder
2Gasket 26Pin
3 Nut 27 Gasket
4 Hammer Case 28 Handle
5D-Handle 29Pin
6 Screw 30 Socket Screw
7 Gasket 31 O-Ring
8 Gasket 32 Valve Bushing
9 O-ring 33 O-Ring
10 Anvil Bush 34 Direction Bar
11 Circlip 35 Steel Ball
12 O-ring 36 Spring
13 Anvil 37 Throttle Bushing
14 Hammer Bushing 38 Throttle Valve Pin
15 Hammer 39 Throttle Valve
16 Cam 40 Inlet Spring
17 Hammer Cage 41 O-Ring
18 Bearing 42 Air Inlet
19 Housing 43 Air Inlet Screen
20 Bearing 44 Hose Connector
21 Cylinder Cover 45 Hex Screw
22 Vane 46 Pin
23 Rotor 47 Pin
24 Pin 48 Trigger

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PARTS DIAGRAM

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DECLARATION OF CONFORMITY