Clarke CAT179 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0120 - ISS1
1/2”STUBBY AIR IMPACT WRENCH
MODEL NO: CAT179
PART NO: 3120196

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INTRODUCTION
Thank you for purchasing this CLARKE Impact Wrench. 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.
SPECIFICATION
Part number 3120196
Dimensions (L x W x H) 118 x 177 x 60 mm
Weight 1.45 kg
Drive size 1/2” square
Min. Hose Size (ID) 8 mm (5/16”)
Air Inlet Size 1/4“BSP Female
Operating Pressure 90 psi (6.2 bar)
Air Consumption 5 cfm (142 l/m) average
Speed /Torque Settings 8500 rpm max free speed
Forward 1 3000 rpm / 200 Nm
Forward 2 3000-7000 rpm / 540 Nm
Forward 3 7000-8500 rpm / 610 Nm
Reverse 8500 rpm / 1000 Nm
Sound Pressure Level (LpA dB) 94.6 dB(A)
Sound Power Level (LwA dB) 105.6 dB(A)
Vibration Level in handle 5.99 m/s2(Uncertainty K = 1.1m/s2)

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GENERAL SAFETY RULES
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 and bystanders away - Do not let children handle
the air tool.
4. DO NOT operate the air tool where there are flammable liquids or gases.
USE OF COMPRESSED AIR POWERED TOOLS
1. ALWAYS stay alert and use common sense - Do not operate the wrench
when you are tired or under the influence of alcohol, drugs or medication.
2. ALWAYS wear eye protectors when using this 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. NEVER 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. NEVER exceed the maximum pressure for the wrench 90 psi / 6.2 bar.
7. Check air hoses for leaks or worn condition before use and ensure that all
connections are secure.
8. Keep the air supply hose away from heat, oil and sharp edges.
9. DO NOT use this tool for any purpose than that described in this manual.
10. DO NOT fit the tool to any stand or clamping device that may damage it.
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.
13. NEVER use the tool if it is defective or operating abnormally.
14. DO NOT damage the tool by applying excessive force.
15. ALWAYS maintain the tool with care. Keep it clean for the best and safest
performance.
16. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
17. DO NOT force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
18. 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 overtightening.
5. ALWAYS ensure that the socket is correctly installed before starting.
6. ALWAYS 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.
8. ALWAYS disconnect from the air supply when changing sockets or when
the impact wrench is not required for immediate use to avoid accidental
starting.
9. NEVER carry the impact wrench by the air hose.
10. ALWAYS use both hands to control the impact wrench.
11. ALWAYS ensure the impact wrench has stopped before putting it down.

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SAFETY SYMBOLS
The above safety symbols are displayed on the body of the impact wrench.
PRODUCT OVERVIEW
Read the instruction
manual
Wear eye protection
Wear ear protection
1½”Square Drive shaft 5 Airline Inlet
2 Trigger 6 Direction/Speed Control
3 Inlet adaptor 7 Hanging support
4 Air exhaust

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THE COMPRESSED AIR SUPPLY
AIR SUPPLY REQUIREMENTS
Use only clean, dry, regulated compressed air as a power source.
Air compressors used with this air 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 air 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 airline 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 airline layout is shown above. If an automatic in-line filter/regulator is
used, it will keep the air tool in good condition, but should be regularly
checked and topped up with oil. SAE 10 oil should be used and the lubricator
adjusted to approx 2 drops per minute.
The minimum hose diameter should be 8mm ID and fittings should have the
same internal dimensions.
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 unclean 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. Remove the plastic blanking plug from the air inlet connection.
2. Pour 2-3 drops of CLARKE airline oil into the inlet port. This should be done
regardless of whether or not a lubricated air supply is to be used.
3. If the air supply is unlubricated, an in-line mini oiler be added to the air tool.
• A mini oiler helps to prolong the life of any air tool.
4. If a mini-oiler is not being used, run a few drops of oil through the tool
before use. It can be entered through the airline connector or via the hose
at the nearest connection to the air supply.
5. Connect a suitable hose as shown
or use the inlet adaptor supplied to
connect directly to the hose.
6. Connect the other end of the hose
to the compressor.
7. Turn on the air supply and check
for air leaks. Rectify any found
before proceeding.
• PTFE tape may be useful for
sealing threaded connections.
8. 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 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.

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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.
Only use the correct impact sockets.
SETTING THE DIRECTION AND SPEED
1. For normal tightening, the wrench
should be operated in the forward
(F) direction.
2. For loosening, the wrench should
be operated in the reverse (R)
direction.
3. To adjust the forward speed, turn
the switch until the desired output
is achieved. A click will be heard
at each of three positions.
• Setting 1 is the least amount of power while setting 3 is the most
powerful.
• The wrench operates at maximum power in reverse. This setting is for
releasing threaded fasteners.
NOTE: Where the torque setting is critical, the final tightening must be by
hand using a calibrated torque wrench.
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR
USE WITH IMPACT TOOLS.
WARNING: WAIT UNTIL THE WRENCH HAS STOPPED ROTATING BEFORE
OPERATING THE FORWARD/REVERSE SWITCH.

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OPERATING THE IMPACT WRENCH
1. Place the socket over the nut/bolt to be tightened or loosened.
2. Squeeze the trigger to start and release the trigger switch to stop the
wrench.
• The square drive will continue to rotate very briefly after the trigger
has been released.
LOOSENING A WHEEL NUT/BOLT
1. Remove any wheel trim, before selecting the appropriate socket and
placing firmly on the square drive of the impact wrench.
2. With the switch in the REVERSE running position, and holding the impact
wrench firmly in BOTH HANDS, squeeze the trigger. The nut/bolt will be
impacted repeatedly until it is loosened. IMPORTANT! Release the trigger as
soon as the nut/bolt begins to loosen.
3. Jack up the vehicle according to the vehicle handbook so that the wheel
is clear of the ground, then proceed to fully undo the wheel nuts/bolts.
4. Soak rusted nuts/bolts in penetrating oil and break any rust seal before
twisting off with the wrench.
TIGHTENING A NUT/BOLT
1. Start the nut/bolt by hand, ensuring it is not cross threaded, then with the
appropriate socket installed on the impact wrench, place it on the nut/
bolt.
2. With the switch in the clockwise (FORWARD) running position, and holding
the wrench firmly in BOTH HANDS, squeeze the trigger.
3. Run each nut/bolt up in turn until it is ‘nipped’ up only - do not tighten.
When all nuts/bolts 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/bolts are tightened. Ensure the final torque applied to the nuts/bolts
meets the vehicle manufacturer’s recommendations.
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 NUTS/BOLTS.

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DISCONNECTING THE AIR SUPPLY
1. Shut down the compressor.
2. Squeeze the trigger of the impact wrench and operate until all the
compressed air is discharged.
3. Once the pressure has been released, disconnect the air supply hose.
MAINTENANCE
1. Routinely drain water from the airline filter and compressor.
2. If no airline lubricator or mini oiler is used, ensure that oil is applied to the
tool on a daily basis through the air inlet connection. Run a few drops of oil
through the tool before use. It may be entered into the air inlet, (ensuring
the screen is clear), or into the hose at the nearest connection to the air
supply.
3. This procedure should be repeated after every two to three hours of use or
at the start of the working day.
4. Keep the body of the tool clean and free from debris.
WEEKLY
1. Check the air inlet screen filter for
blockage and clean if necessary.
CLEANING & OVERHAUL
1. Grit or gum deposits in the tool
may reduce efficiency.
2. After extensive use, remove the
inlet screen filter and flush out the
mechanism with gum solvent oil or
an equal mixture of CLARKE air-
line oil and paraffin. Allow to dry before use.
3. If the tool still runs erratically or becomes inefficient, and the air supply is of
good quality, it may be necessary to dismantle the air motor and replace
worn or damaged parts. You may prefer to take the tool to your CLARKE
dealer if internal maintenance is required.
WARNING: MAKE SURE THAT THE WRENCH IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

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4. The air tool may be dismantled by unfastening the bolts and removing the
rear cover prior to replacing any worn or damaged parts.
5. While in a dismantled state, it may be desirable to grease the hammer
mechanism and apply a small amount of good quality bearing grease.
• This may be better left to your CLARKE dealer.
PERFORMANCE
Please note that outside factors may affect the operation and efficiency of
any air tool.
These include reduced compressor output, excessive drain on the airline,
moisture ingress, restrictions in the air-line such as the use of connectors of
incorrect size or poor condition which will reduce the air supply.
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.
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 depress the trigger in order to lubricate
the internal parts.
When not in use, the tool should be disconnected from the air supply and
stored in a dry place out of the reach of children. Avoid storing in a damp
environment.
ACCESSORIES
A wide range of accessories is available including filter/regulators, lubricators,
high-pressure hoses (5 to 50 metres) etc.
CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
SUITABLE CLARKE IMPACT SOCKET SETS INCLUDE:
CIS12/11 11 piece 1/2” Metric Impact Socket Set part no 3110437
CIS12/17 17 piece 1/2” A/F Deep Impact Socket Set part no 1800311
CIS12/10 1/2” Metric 6 point Impact Socket Set part no 3110875
CIS12/3M 3pc 1/2” drive non-slip socket set part no 1700732
CIS12/6SB 6-piece impact Spline socket set part no 1700726

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
the impact wrench.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force applied
to the impact wrench.
2. Return to CLARKE dealer
for repair.
3. 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. Motor parts jammed
with gum/dirt.
2. Regulator in closed
position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
cleanliness.
2. Adjust regulator to open
position.
3. Operate tool in short
bursts.
Tool will not run. Air
flows freely from
exhaust.
1. 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. O-rings damaged or
ill-fitting in seat.
1. Return to CLARKE dealer
for repair.

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DECLARATION OF CONFORMITY

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PARTS DIAGRAM

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PARTS LIST
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.
No Description No Description
1 Bolt 19 Pin 3*10
2 Spring washer 20 Cylinder rear cover
3Bodycover 21Bearing
4 O-ring 7.5x1.8 22 Trigger
5 Circlip 23 Set screw
6 Anvil collar 24 Plug
7 Anvil 25 Valve pin
8 Hammer cage 26 Valve spring
9 Hammer dog 27 Exhaust cap
10 Hammer pin 28 Inlet connector
11 Seal 29 Circlip
12 Hook 30 Seal
13 Main body 31 Rear cover
14 Bearing 32 O-ring 9*2
15 Cylinder head 33 Switch
16 Rotor blade 34 Steel ball
17 Rotor 35 Spring
18 Cylinder