Clarke CAT96 Instruction Manual

0104
1/2” IMPACT WRENCH SET
MODEL NO: CAT 231C + CAT 96
PART No: 3110425 & 3110852
1/2” IMPACT WRENCH SET
OPERATION & MAINTENANCE
INSTRUCTIONS

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 machines data plate
Fig.1
SPECIFICATIONS
Model:........................................................CAT 231c
Part No:......................................................3110425
Square Drive:.............................................1/2”
Maximum Torque:.....................................240 lbs/ft
Air Inlet Size:..............................................1/4” BSP
Minimum Hose Size:..................................5/16” (8mm) ID
Nominal Air Consumption:...................... 4 CFM
Maximum Air Pressure:.............................90 PSI (6.2bar)
Weight:......................................................4.0 kg
Bolt Capacity:...........................................5/16” (16mm)
Socket’s:..9, 10, 11, 13, 14, 17, 19, 22, 24 and 27mm
Vibration Emmisions, Refer to notes on pages 7 and 8

CLARKE 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 affect your statutory rights.
Please read these instructions carefully before operating the tool
Thank you for purchasing this CLARKE Air 1/2” Impact Wrench.
Before using the device, please read this manual thoroughly and carefully follow
all instructions given. This is for your own safety and that of others around you, and
is also to helpyou achieve long and trouble free service from your new tool.
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 Sales Department on 01992 565300
PARTS & SERVICE TEL: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]

SAFETY PRECAUTIONS
IMPORTANT
Failure to follow these precautions could
result in personal injury, and/or damage to
property.
❐When operating this tool, ALWAYS wear:
a. approved impact resistant SAFETY
GOGGLES. (Eye glasses are NOT
safety glasses)
b. a DUST MASK
c. EAR DEFENDERS
d. a good pair of INDUSTRIAL GLOVES
❐ALWAYS disconnect the tool when not
in use, and before carrying out any
maintenance
❐ALWAYS keep a safe distance between
yourself and other people when using
the tool.
❐ALWAYS maintain the tool with care.Keep
it clean for best and safest performance.
❐NEVER wear ill fitting clothing, remove
watches and rings.
❐Quick change couplings should not be
located at the tool. They add weight
and could fail due to vibration.
❐DO NOT over-reach. Keep your proper
footing and balance at all times.
❐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 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 leaks or worn
condition before use, and ensure that
all connections are secure.
❐DO NOT exceed 90 PSI at the tool.
❐DO NOT modify the tool in any way.
❐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.
❐ALWAYS use screens to protect people
in the vicinity from flying debris.
❐NEVER point the tool at anyone.
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.
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
(6.1bar), 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.
The recommended procedure to connect
this tool to an air supply, is shown at fig. 1 on
inside front cover.
The air inlet used for connecting 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 6mm (¼") ID., and fittings
should have the same inside dimensions.
ASSEMBLY
Connect a suitable hose to the Wrench using
a ¼” hose adapter,(A whip hose with Quick
Fit coupling is available from your CLARKE
dealer). then connect the other end to the
airline.
NOTE: ensure the airline is turned off.
Your Wrench is now ready for use.
IMPORTANT:
The use of parts other than CLARKE
replacement parts may result in safety
hazards, decreased tool performance
and may invalidate your warranty.

Before starting work drain any water from
the air tank and blow condensation from
the air line. Drain compressor more
frequently in hot humid weather.
1. Ensure air is turned OFF, select
appropriate impact socket, which
must be in good condition, and fits the
tool shank and nut closely.
2. Adjust the direction of rotation
forward or reverse, this is achieved
using the Reverse valve knob situated
just above the trigger (throttle Lever).
To adjust direction, push button in or
out.
3. Screw the regulator (Item 12) in
(clockwise) to it’s lowest power
setting, and apply the wrench to the
nut or bolt.
4. Depress trigger and gradually adjust
the regulator untill the fastener starts
to move in the direction which it was
set.The tool is now set to duplicate that
tightness.
NOTE:
When critical torque values are not
required, turn the nut or bolt one quater
to one half a turn untill it fits snugly -
slightly more if gaskets are used between
surfaces.
For additional power on disassembly
work turn reulator out to it’s highest
setting, (maximum pressure).
IMPORTANT
Where torque settings are critical, the
final tightening of nuts or bolts must be
by hand, using a calibrated torque
wrench.
WARNING
NEVER use standard hand sockets, as
these could shatter with serious
consequences, use only impact sockets,
which must be in good conditon.
OPERATING INSTRUCTIONS MAINTENANCE
Daily before use.
1. Drain water from air tank, air line and
compressor.
2. Check and clean, if necessary, the
air inlet gauze filter .
3. Pour a few drops of CLARKE Air Line
Oil (approx 3cc), 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.
If the wrench 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.
For lubricating the air motor when in
operation, an air line lubricator should
be used, with Clarke Air Line Oil, adjusted
to 2 drops per minute.
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 dis-assembled, thoroughly cleaned,
dried and re-assembled.
If the tool runs erratically or becomes
inefficient, and the air supply is sound,
dismantle the air motor and replace
worn or damaged parts, or take the tool
to your CLARKE dealer.

PARTS DIAGRAM
PARTS LIST
1 504W01 Housing 1
2 504W02 Valve Bushing 1
3 504W03 Reverse Valve 1
4 504W04 Trigger 1
5 504W05 Pin 1
6 504W06 Valve Stem 1
7 504W07 Air Inlet 1
8 504W08 Ball Set 1
9 504W09 Spring 1
10 504W10 Steel Ball 1
11 504W11 Screen 1
12 504W12 Air regulator 1
13 504W13 ‘O’ Ring 1
14 504W14 Spring 1
15 504W15 Oil Seal 1
16 504W16 Screw 1
17 504W17 Anvil Bushing 1
18 504W18 Anvil (1/2”) 1
19 504W19 Hammer Cage 1
20 504W20 Hammer Pin 1
21 504W21 Hammer Dog 1
22 504W22 Ddrive Cam 1
23 504W13 Pin 1
24 504W24 Cylinder 1
25 504W25 Rotor 1
26 504W26 Rotor Blade 6
Index Part Description Index Part Description
No. No. Qty No. No. Qty
27 504W27 Front End Plate 1
28 CA6001 Ball Bearing 2
29 504W29 Rear End Plate 1
30 504W30 Pin 1
31 504W31 Spring 1
32 504W32 Pin 1
33 504W33 gasket 1
34 504W34 Rear Cover 1
35 504W35 Washer 4
36 504W36 Screw 4
37 504W37 Protecting Rubber 1
38 504W38 Exhaust Deflector 1
39 504W39 Screw 2
40 504W40 Screw 1
41 504W41 Anvil Collar 1
42 504W42 ‘O’ Ring 1
43 504W43 Rubber 1
44 504W44 Screw 1
45 504W45 Oil Seal 1

- 7 -
MODEL No: CAT231C
DESCRIPTION: 1/2” IMPACT WRENCH
Declared vibration emmission value in accordance
with EN12096
Measured vibration emmission value - a: m/s2
Uncertainty value - K: This
Page Intentionally Left BlanThis Page
Intentionally Left Blanm/s2
Highest measured reading in a single plane m/s2
Values determined according to EN28622-1
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 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 specification panel below.
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 above 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.