Clarke CAT48 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
3/4”(20mm)
HEAVY DUTY IMPACT WRENCH
3/4”(20mm)
HEAVY DUTY IMPACT WRENCH
MODEL - CAT 48
0805

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 HandArm 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 7.
HAND-ARMVIBRATION
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/s2are 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.
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3
Please read these instructions carefully before operating the tool
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.
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.
SPECIFICATIONS
Drive Size ................................................................. 3/4” square
Max. Torque ............................................................ 500lbft
Air Inlet .................................................................... 1/4" BSP
Min. Hose Size (ID) .................................................. 8mm (5/16")
Ave. Air Consumption ............................................ 7.5 CFM
Air Pressure Max. .................................................... 90 PSI (6.2 BAR)
Net Weight .............................................................. 5 kg
Vibration Level* ...................................................... 16.49m/s2*
Sound Pressure Level** .......................................... 107dBA **
* Please refer to ‘Hand Arm Vibration’ on Page 2. The total, cumulative time that
this tool should be used, per day, should be measured in minutes .
Declared vibration emmission value in accordance with EN12096
Measured vibration emmission value - a: .............................. 16.49m/s2
Uncertainty value - K: ............................................................... 3.20m/s2
Highest measured reading in a single plane .............................. 16.45m/s2
Values determined according to EN28622-2
** Sound Pressure levels were determined when tightening a 20mm bolt, in a
horizontal plane, to 500lbft.
Levels may vary depending upon conditions of use. A risk assessment should
be carried out, on site, to determine actual levels and appropriate measures
taken to avoid damage to hearing.

SAFETY PRECAUTIONS
IMPORTANT
Failure to follow these precautions could result in personal injury, and/or
damage to property.
1. ALWAYS wear BS approved impact resistant safety goggles. (Eye glasses are
NOT safety glasses).
2. ALWAYS wear face or dust mask (where dust is created).
3. ALWAYS wear BS approved Ear Defenders, as considerable noise is generated,
depending upon application. (see specifications)
4. ALWAYS disconnect the tool when not in use, before changing accessories
and before carrying out any maintenance
5. ALWAYS have trigger in the OFF position when connecting to an air supply.
6. ALWAYS keep a safe distance between yourself and other people when using
the tool.
7. ALWAYS maintain the tool with care. Keep it clean for best and safest
performance.
8. DO NOT wear ill fitting clothing, remove watches and rings.
9. DO NOT locate Quick Change couplings at the tool. They add weight and
could fail due to vibration.
10. DO NOT over-reach. Keep your proper footing and balance at all times.
11. DO NOT force or misuse the tool. It will do a better and safer job at the rate for
which it was designed.
12. DO NOT abuse hoses or connectors. NEVER carry a tool by the hose, or yank it
to disconnect from the air supply. Keep hoses away from heat, oil and sharp
edges. Check hoses for weak or worn condition before use, and ensure that
all connections are secure.
13. DO NOT exceed 90 psi at the tool.
14. DO NOT use hand sockets, as these could shatter with serious consequences.
Use only impact wrench sockets, which MUST be in good condition.
15. DO NOT use extension bars unless absolutely necessary - use deep sockets
when possible.
16. NEVER operate the tool unless it is attached to the work - the speed of rotation
could cause the socket to be thrown from the wrench
17. DO NOT modify the tool in any way.
18. DO NOT allow anyone to use the tool unless they are physically capable of
handling its’ bulk weight and power.
4

AIR SUPPLY
Tools of this type, operate on a wide range of air pressures. It is recommended that
air pressure to this tool does not exceed 90 PSI, at the tool when running. Higher
pressure and unclean air, will shorten the tools’ life because of faster wear, and
could be a safety hazard.
Water in the air line will cause damage to the tool, ensure it is properly maintained
at all times.
Filter
Filter / Regulator
Air
Supply
Airline Hose
Airline Hose
Regulator
Fig.1
OPERATION
Select an appropriate impact socket, which must be in good condition, and fits
the tool shank and nut closely. (NEVER use standard hand sockets)
Forward and Reverse is obtained by pushing the lever, on the side of the tool, to
the ‘F’ or ‘R’ position.
Tool power is adjusted by turning the knob, at the base of the tool, to one of the
settings etched in the knob. The lower the number, the lower the power setting.
Turn the regulator to its lowest setting, then apply the wrench to a nut or bolt of
known tightness (or torque setting), size, thread pitch, and thread condition as
those on the job.
Start the tool, in the FORWARD position, and gradually turn the regulator until the
nut or bolt moves very slightly in the direction in which it was set. The tool is now set
to duplicate that tightness. For future use, note that setting.
When critical torque values are not required, turn nut or bolt until it fits snugly, and
then turn a further one quarter to one half a turn - slightly more if gaskets are used
between surfaces.
For additional power on disassembly work, turn the regulator to its highest setting.
This tool is rated at 3/4" bolt size, and is downgraded for spring ‘U’ bolts, tie bolts,
long cap screws, double depth nuts, badly rusted conditions, and spring loaded
fasteners as these conditions absorb much of the impact power.
Soak rusted nuts in penetrating oil, and break rust seal before turning off with the tool.
IMPORTANT: Where the torque setting is critical, the final tightening of nuts or bolts,
must be by hand using a properly calibrated torque wrench.
The recommended procedure to con-
nect this tool to an air supply, is shown at
fig.1 below. The air inlet used for con-
necting air supply, has a standard ¼”
BSP thread.
Line pressure, or hose inside diameter,
should be increased to compensate for
unusually long air hoses (over 10m).
Minimum hose diameter should be
8mm (5/16") ID., and fittings should
have the same inside dimensions.
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MAINTENANCE
Daily
1. Before use, drain water from air tank, air line and compressor.
2. If no line Lubricator is used, ensure that oil is applied to the tool (see below).
Weekly
Clean the air inlet filter screen (within parts list item 31).
Monthly
Oil the Hammer mechanism at least once per month, by removing the hex. socket
screw in the side of the tool, and injecting a few drops of oil, (SAE30).
For lubricating the air motor, an air line lubricator should be used, with Clarke Air Line
Oil, adjusted to 2 drops per minute. If this is not possible, run a few drops of oil through
the tool. 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 run the tool.
Clarke Air Line Oil is available from your CLARKE dealer, part no. 3050825.
Be aware 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.
Grit or gum deposits in the tool may also reduce efficiency. This condition can be corrected
by cleaning the air strainer and flushing out the tool with gum solvent oil, or failing this, the
tool should be disassembled, thoroughly cleaned, dried and reassembled.
If the tool runs erratically or becomes inefficient, and the air supply is sound,
dismantle the air motor and hammer mechanism and replace worn or damaged
parts, or take the tool to your CLARKE dealer.
Keep the tool clean at all times, and ensure that the hex. socket screws securing
the hammer case remain tight.
SPARE PARTS AND SERVICING
Contact your nearest dealer, or CLARKE International, on one of the following numbers.
PARTS & SERVICE - 020 8988 7400
PARTS & SERVICE E-Mail: Parts(or Service)@clarkeinternational.com
ACCESSORIES
A wide range of Airline accessories is available, including Filter/Regulators,
Lubricators, High Pressure Hoses from 5 to 100 Metres, etc.
Contact your CLARKE dealer for further information, or CLARKE International
Spare Parts Department on 020 8988 7400
DISPOSAL
When disposing of this product, ensure it is disposed of according to all l.ocal
ordinances

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PARTS LIST
Item Description Qty Part No. Item Description Qty Part No.
1 Protecting Rubber 1 28-0030
2 Seal 1 00-4205
3 Housing 1 28-0001
4 Screw 1 00-0614
5 Anvil Bushing 1 28-0014
6 Anvil Collar 1 28-0016
7 O-ring 1 00-4118
8 Spacer 1 28-0017
9 Anvil 1 28-0015
10 Hammer Pin 1 28-0019
11 Hammer Cage 1 28-0018
12 Hammer 1 28-0020
13 Cam 1 28-0021
14 Seal 2 00-4206
15 O-ring 1 00-4108
16 Front Plate 1 28-0022
17 Rotor Blade 6 28-0024
18 Rotor 1 28-0023
19 Cylinder 1 28-0025
20 Washer 1 28-0034
21 Ball Bearing 1 00-2312
22 Rear Plate 1 28-0026
23 Rear Cover 1 28-0028
24 Washer 4 00-1803
25 Screw 4 00-0119
26 Screw 3 00-0110
27 Rear Rubber 1 28-0031
28 Washer 3 00-1802
29 O-ring 3 00-4111
30 Valve Sleeve 1 28-0002
31 Reverse Valve 1 28-0003
32 Rear Gasket 1 28-0027
33 O-ring 1 00-4106
34 Air Regulator 2 28-0008
35 Screw 2 00-0802
36 Exhaust Deflector 1 28-0012
37 Pin 1 28-0009
38 Spring 1 28-1031
39 Screw 1 00-0610
40 Trigger 1 28-0004
41 Pin 1 00-3301
42 Pin 1 00-3305
43 Valve Stem 1 28-0005
44 Spring 1 28-0011
45 Hose Adapter 1 25-1010
46 Ball Bearing 1 00-2313
47 O-ring 1 00-4114