Clarke CAT78 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0813
IMPACT WRENCH
MODEL NO: CAT78
PART NO: 3110790

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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.
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. Please pay particular attention to all sections of these instructions
that display warning symbols and notices.
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.

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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 impact
wrench.
4. Do not operate the impact wrench where there are flammable liquids or
gases.
5. Keep the air supply hose away from heat, oil and sharp edges.
6. Do not fit the impact wrench to any stand or clamping device that may
damage the wrench.
USE
1. 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.
2. Always wear eye protectors when using the impact wrench - eye
protectors must provide protection from flying particles from the front and
the side.
3. Always wear ear protectors when using the impact wrench.
4. Do not overreach - Keep proper footing and balance at all times.
5. Never use any type of bottled gas as a source of power for the impact
wrench.
6. Do not connect the air supply hose with your finger on the trigger of the
impact wrench.
7. Do not exceed the maximum pressure for the impact wrench: 90 psi / 6.2
bar.
8. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
9. Do not use the impact wrench for any other purpose than that described
in this manual.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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10. Do not carry out any alterations or modifications to the impact wrench.
11. Always disconnect from the air supply when:
• Performing any maintenance
• The impact wrench is not in use.
• The impact wrench will be left unattended.
• Moving to another work area.
• Passing the impact wrench to another person.
12. Never use the impact wrench if it is defective or operating abnormally.
13. The impact wrench should be serviced at regular intervals by qualified
service personnel.
14. Avoid damaging the impact wrench for example by applying excessive
force of any kind.
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. Do not remove any labels. Damaged labels should be replaced.
19. 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.
20. NEVER use standard sockets. These may shatter with serious consequences.
Use ONLY impact sockets.
TRANSPORTATION
1. Never carry the impact wrench by the air supply hose.
2. Never carry the impact wrench with your finger on the trigger.
STORAGE
1. 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).
2. Avoid storing the impact wrench in environments where the temperature is
below 0oC.

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OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Anvil 4 Speed Control Regulator
2 Forward/Reverse Valve 5 1/4” BSP (Female Air Inlet)
3Trigger

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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 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. 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
minimum hose diameter should be 5/16”(8mm) ID and fittings should
have the same internal dimensions.
• Never exceed the maximum operating pressure for the wrench. 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.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.
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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• 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. SAE 10 oil should be
used, and the lubricator adjusted to approx 2 drops per minute.
BEFORE USE
NOTE: Ensure the compressor is turned off.
1. If required, connect an in-line mini
oiler to the tool.
• A mini oiler helps to prolong the
life of the impact wrench.
Remove the oil fill screw from
the side of the mini oiler and fill
with Air-line Oil available from
your CLARKE dealer. Replace
the screw before using the
wrench.
2. 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 inlet strainer or via the
hose at the nearest connection to
the air supply.
3. Connect a suitable hose as shown.
4. Connect the other end of the hose
to the compressor.
5. 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 FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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USING THE FORWARD/REVERSE BUTTON
Forward/Reverse rotation is selected by pushing the Forward/Reverse control
forward or backward as required.
1. For normal tightening, the wrench
should be operated in the forward
direction.
2. For loosening, the wrench should
be operated in the reverse
direction.
FITTING THE IMPACT SOCKET
1. Select the impact socket you
require, which must be in good
condition and fit the tool exactly.
Push the socket onto the anvil as
shown.
WARNING: WAIT UNTIL THE ANVIL HAS STOPPED ROTATING BEFORE
OPERATING THE FORWARD/REVERSE BUTTON.
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR
USE WITH IMPACT TOOLS.

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OPERATION
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 POWER
1. To adjust the power, set the air
regulator to one of the 5 settings
available.(Setting 1-Low, 5 -High)
If you start by turning the regulator to
its lowest setting and applying the
wrench to a nut of known tightness (or
torque setting), you can then
gradually turn the regulator until the
nut or bolt moves very slightly in the
direction in which it was set. The
wrench is now set to replicate that tightness. Note the setting for future use.
When critical torque values are not required, tighten the nut or bolt until
secure, then turn a further quarter to a half turn, assuming no gaskets are
being used between surfaces. For additional power on disassembly work, turn
the regulator to its highest setting.
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 manual for the procedure to shut down
and release the compressed air.
2. Once the pressure has been released, disconnect the air supply hose from
the impact wrench.
Store the wrench safely in its box in a dry, secure environment.

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MAINTENANCE
DAILY
• Before use, drain water from the air tank, air line and compressor.
• Pour a few drops of CLARKE airline oil, into the air inlet. This should be
carried out regardless of whether or not an in-line mini oiler is used. If
an in-line mini oiler is not used, this procedure should be repeated
after every two to three hours of use.
WEEKLY
• Check the air inlet screen filter
for blockage and clean if
necessary.
• Oil can be added directly into
the internal working parts by
way of the oil port located on
the right hand side of the tool
body.
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
If the tool runs erratically or becomes inefficient although the air supply is in
good order, it may be necessary to dismantle the air motor and impacting
clutch and replace any worn or damaged parts. Such servicing and repair
work should be carried out by qualified service technicians.
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.
WARNING: MAKE SURE THAT THE IMPACT WRENCH IS DISCONNECTED
FROM THE AIR SUPPLY BEFORE STARTING ANY CLEANING, OR
MAINTENANCE PROCEDURES.

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Grit or gum deposits inside the tool may also reduce its efficiency. This
condition can be corrected by cleaning out the air strainer and flushing out
the tool with gum solvent or oil, or failing this, the motor may require
dismantling.
**Clarke Air Line Oil (part no. 3050825) is available from your 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 run the tool for 5 seconds in order to
lubricate the internal parts.
When not in use, disconnect from air supply, clean tool and store in a safe, dry
place.
SPECIFICATIONS
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.
Model Number CAT78
Part Number 3110790
Anvil Size 3/8”(9.5mm)
Maximum Torque 75 ft/lb
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4.2 cfm
Min Air Inlet Hose Size 5/16“BSP
Sound Pressure Level (LpA dB) 85 dB(A)
Sound Power Level (LwA dB) 96.8 dB(A)
Vibration Levels 2.8 m/s2 at the main handle
Uncertainty Value 1.4 m/s2
Highest measured reading in a single plain
3.18 m/s2
Weight 1.3 kg

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TROUBLESHOOTING
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 CLARKE International
Service Department on 01992 565333.
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
tool.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force
applied to the tool.
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. Throttle O-rings
damaged or ill-fitting
in seat.
1. Return to Clarke dealer
for repair.

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PARTS LIST & DIAGRAM

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PARTS LIST & DIAGRAM
No Description No Description
1 Rubber Nose Guard 27 Ball Bearing
2 Oil Seal 28 N/A
3 Oiler Screw 29 Housing Band
4 Motor Housing 30 Rear End Cap
5 Reverse Valve Pin 31 Spring Washer
6 Reverse Valve Spring 32 Set Screw
7 Set Screw 33 Screw
8 Housing Bush 34 Exhaust Cover
9 N/A 35 Throttle Lever
10 Socket Retaining Ring 36 Pin
11 O-Ring 37 Push Pin
12 Anvil 38 O-Ring
13 Reverse Valve 39 Gasket
14 Hammer Cage Pin 40 Pin
15 Hammer Cage 41 Valve Block
16 Cam 42 O-Ring
17 Dog 43 Regulator Valve
18 Ball Bearing 44 Spring Washer
19 Oil Seal 45 Set Screw
20 O-Ring 46 O-Ring
21 Front End Plate 47 Throttle Valve
22 Motor Pin 48 N/A
23 Rotor Blade (Set) 49 Throttle Valve Spring
24 Rotor 50 Hose Adaptor
25 Cylinder 51 N/A
26 Rear End Plate 53 O-Ring

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DECLARATION OF CONFORMITY