Clarke Air CAT232 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0215
14 PIECE AIR TOOL KIT
MODEL NO: CAT232
PART NO: 3110432

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INTRODUCTION
Thank you for purchasing this CLARKE Air Tool Kit.
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.
Your tool kit has been designed to give long and trouble free service. If,
however, having followed the instructions in this booklet carefully, you
encounter problems, take the unit to your local CLARKE dealer.roblems, take
the unit to your local CLARKE dealer.
SYMBOLS
Please read all of the safety and operating instructions carefully before using
this product. The following safety symbols may be found on the air tools.
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. Wear dust mask

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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 POWER TOOLS
1. Stay alert and use common sense - do not operate the air 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.
3. Always wear ear protectors when using the air tool.
4. Do not overreach - Keep proper footing and balance at all times.
5. Never use oxygen, CO2, combustible gasses or any type of bottled gas as
a source of power for the tool.
6. Do not connect the air supply hose with your finger on the trigger.
7. Do not exceed the maximum pressure for the tool of 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 tool for any other purpose than that described in this
manual.
10. Keep the air supply hose away from heat, oil and sharp edges.
11. Do not fit the tool to any stand or clamping device that may damage it.
12. Do not carry out any alterations or modifications to the tool.
13. Always disconnect from the air supply when:
• Performing any maintenance.
• The tool is not in use.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• The tool will be left unattended.
• Moving to another work area.
• Passing the tool to another person.
14. Never use the tool if it is defective or operating abnormally.
15. The tool should be serviced at regular intervals by qualified service
personnel.
16. Avoid damaging the tool for example by applying excessive force of any
kind.
17. Always maintain the tool with care. Keep it clean for the best and safest
performance.
18. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
19. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
20. Do not remove any labels. Damaged labels should be replaced.
21. 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 in the manner and for the functions
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, never allow the wrench to impact more than 8 times - to avoid over
tightening - 3 to 4 impacts is normally sufficient.
5. ALWAYS ensure that the socket is correctly installed before switching on.
6. ALWAYS only use sockets which are specified for impact wrench use.
7. Due to the possible presence of asbestos dust from brake linings, always
wear suitable respiratory protection.
8. Never carry the impact wrench by the air supply hose.

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9. ALWAYS disconnect from the air supply when changing bits or when the
wrench is not required for immediate use in order 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.
TRANSPORTATION AND STORAGE
1. Never carry the tool by the air supply hose.
2. Never carry the tool with your finger on the trigger.
3. 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 (preferably in a locked
cabinet).
4. Avoid storing the tool in environments where the temperature is below 0oC.
5. Additionally, please keep these instructions in a safe place for future
reference.
BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the blanking plug from the inlet connection of the tool.
2. If required, connect an in-line mini oiler to the tool.
• A mini oiler helps to prolong the life of the air tool.
3. 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 air inlet or via the hose at the
nearest connection to the air supply.
4. Connect a suitable hose to the air inlet as shown.
5. Connect the other end of the hose to the compressor.
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 SUPPLIES.

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CONTENTS
The CAT232 Air Tool KIt includes a 1/2” Impact Wrench and 3/8” Reversible
Ratchet Wrench together with the accessories as follows:
• CAT23C Impact Wrench
• CAT21B Reversible Ratchet
• 10 Impact Sockets
• 1/2” female adaptor
• 3/8” male adaptor
When opening the case for the first time, check that all the items are present.
Any damage or deficiency should be reported to your CLARKE dealer
immediately.

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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. Always consult the
machine’s data plate.
Model Number CAT23C Impact
Wrench
CAT21B Reversible
Ratchet Wrench
Dimensions (L x W x H) 180 x 60 x 180 mm 154 mm long
Weight 2.1 kg 1.0 kg
Air Inlet Size 1/4“BSP (female) 1/4“BSP (female)
Operating Pressure 90 psi (6.2 bar) 90 psi (6.2 bar)
Air Consumption 4.5 cfm at max load 4 cfm at max load
No Load Speed 1500 rpm @ 90psi 1500 rpm @ 90psi
Sound Pressure Level (LpA dB) 94 dB(A) 89.6 dB(A)
Sound Power Level (LwA dB) 105 dB(A) 101.5 dB(A)
Vibration Levels 10.4 m/s29.13 m/s2
Drive Size 1/2” Square 3/8” Square
Max Tightening Torque 260 ft/lb +/-10% 50 ft.lb +/-10%
Max Bolt Capacity 5/8” (16mm) n/a

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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. SAE 10 oil should be
used, and the lubricator adjusted to approx 2 drops per minute.
• 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.
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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OPERATION - IMPACT WRENCH
1. Select an appropriate impact socket, which must be in good condition,
and fits the anvil and nut closely. Use only square drive impact wrench
sockets as listed on page 14. (NEVER use standard hand sockets).
2. Select Forward or Reverse drive by moving the rod, in the body of the
wrench, to the ‘F’ or ‘R’ position. Always check the direction of rotation
before operation. Select the appropriate lever when the spindle is moving.
3. Squeeze the trigger to start the wrench. Release the trigger to stop.
4. Turn the airline 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.
5. Start the wrench, in the FORWARD position, and gradually turn the air
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 specific setting.
6. 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.
7. For additional power during disassembly work, turn the air line regulator to
its highest setting.
8. This tool is rated at 5/8" 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.
9. Turn off the wrench as soon as the impact sound is heard.
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.
CAUTION: ALWAYS BE SURE THAT THE TOOL IS SWITCHED OFF BEFORE
ATTACHING OR REMOVING A SOCKET. ALWAYS TAKE CARE TO USE THE
CORRECT SIZE SOCKET FOR BOLTS AND NUTS. AN INCORRECT SOCKET
WILL CAUSE DAMAGE TO THE BOLT OR NUT.

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IMPORTANT: Release the trigger immediately 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.
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 switch 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 for 3 to 4 impacts only 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 pressure released.
2. Once the pressure has been released, disconnect the air supply hose from
the tool.
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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OPERATION
USING THE DIRECTION CONTROL
1. To select the direction of rotation
turn the direction control as
follows:
• For tightening, turn the direction
control anti-clockwise to F
(Forward).
• For loosening, turn the direction
control clockwise to R (Reverse).
USING THE AIR RATCHET
1. Select the socket you require.
• Push the socket onto the square
drive shaft. It clicks into place
when secure.
2. Place the socket over the nut.
• Take care that the socket is
firmly engaged.
3. Squeeze the trigger against the
body of the tool to start.
4. Release the trigger to stop the tool.
5. Always ensure the tool has stopped before putting it down.
6. When releasing very tight fastenings initially break loose by hand. Squeeze
the trigger and the air tool will complete the job.
7. If necessary, use penetrating oil to assist in freeing off rusted fasteners.
8. When assembling, start turning fasteners by hand, then set the rotation
forward or reverse. Apply the tool gently and squeeze the trigger to tighten
with power.
9. Final tightening should be completed by hand.
WARNING: ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING
BEFORE OPERATING THE DIRECTION CONTROL.

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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. Once the pressure has been released, disconnect the air supply hose from
the tool.
TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
drill.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force
applied to the drill.
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. 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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MAINTENANCE
ROUTINE
1. Before use, drain water from air reservoir, air line and compressor as
appropriate.
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, 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 operate the tool.
Clarke Air-line Oil is available from your CLARKE dealer, part no. 3050825.
CLEANING
1. Check the air inlet strainer for
blockage and clean if necessary.
2. Keep the body of each tool clean
and free from debris.
3. 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. This is better left to your Clarke dealer.
4. After extensive use, remove the inlet screen filter and flush out the
mechanism with gum solvent oil or an equal mixture of SAE No10 oil and
paraffin. Allow to dry before use.
SERVICE AND REPAIR
1. All bearings etc, in this machine are lubricated with sufficient high grade
lubricant for the machines lifetime under normal operating conditions,
therefore no further lubrication is required.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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2. Be aware that outside factors may effect the wrench’s operation and
efficiency, These may include reduced compressor output, excessive drain
on the airline, moisture in suspension or restrictions in the line, or the use of
connectors of improper size or poor condition which will reduce air supply.
3. Any major servicing and repairs should be carried out by your local CLARKE
dealer or a qualified service technician.
4. If the tool runs erratically or becomes inefficient, and the air supply is of
good quality, it may be necessary to dismantle the air motor and hammer
mechanism and replace worn or damaged parts. You may prefer to take
the tool to your CLARKE dealer if internal maintenance is required.
5. Your Clarke air tool has been designed to give long and 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
1. 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.
2. When not in use, disconnect from air supply, clean tools and store in the
moulded case provided. When storing, ensure the blanking plug is
replaced on the airline connector once the airline is disconnected.
**Clarke Airline Oil is available from your CLARKE dealer: Part No. 3050825.
ACCESSORIES
A wide range of airline accessories is available from your nearest CLARKE
dealer, for further information, contact your nearest dealer, or telephone
CLARKE International Sales Department on 01992 565300.
Suitable air line accessories include air filter/regulators, lubricators, hoses, snap
couplings, clips, gauges, valves.
Suitable Impact Wrench compatible socket sets include the following:
3110437 CAT37B 1 piece 1/2”square drive (metric)
1800310 CIS12/17 17 piece 1/2”square drive (metric/AF)
1800305 CIS9/32 32 piece 3/8” & 1/2”square drive (metric/AF)
1800345 CIS12/7M 7 piece 1/2”square drive universal joint (metric)
1800350 CIS12/7MD 7 piece 1/2”square drive universal joint (deep) metric
1800355 CIS12/6H 6 piece 1/2”square drive hex key set (metric)
1800360 CIS12/6S 7 piece 1/2”square drive TRX-Star

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PARTS DIAGRAM - IMPACT WRENCH

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PARTS LIST-CUT - IMPACT WRENCH
No Description No Description
1 Housing 24 Cylinder
2 Valve Bushing 25 Rotor
3 Reverse Valve 26 Rotor Blade
4Trigger 27FrontEndPlate
5 Pin 28 Ball Bearing
6 Valve Stem 29 Rear End Plate
7 Air Inlet 30 Pin
8 Ball Set 31 Spring
9 Spring 32 Pin
10 Steel Ball 33 Gasket
11 Screen 34 Rear Cover
12 Air Regulator 35 Washer
13 O-Ring 36 Screw
14 Spring 37 Rubber Protector
15 Oil Seal 38 Exhaust Deflector
16 Screw 39 Screw
17 Anvil Bushing 40 Screw
18 Anvil (1/2”) 41 Anvil Collar
19 Hammer Cage 42 O-Ring
20 Hammer Pin 43 Rubber Seal
21 Hammer Dog 44 Screw
22 Drive Cam 45 Oil Seal
23 Pin

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PARTS DIAGRAM - RATCHET WRENCH

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PARTS LIST - RATCHET WRENCH
No Description No Description
1 Air Inlet 22 Gear
2 Handle 23 Gear Plate
3 Throttle Lever 24 Clamp Housing
4 Pin 25 Bearing
5 Throttle Bushing 26 Ratchet Housing
6 Valve - Throttle 27 Pin - Lock
7 O-Ring 28 Spring - Ratchet
8 Spring - Throttle 29 Button - Reverse
9 O-Ring 30 Washer
10 Plug - Throttle Valve 31 Pin
11 Bearing Cap 32 Pawl - Ratchet
12 Bearing 33 n/a
13 Plate - Front End 34 n/a
14 Pin 35 Washer
15 Rotor 36 Retaining Ring
16 Rotor Blade 37 Bearing
17 Cylinder 38 Crankshaft
18 Plate - Rear End 39 Bushing - Drive
19 Bearing 40 Yoke - Ratchet
20 Bearing Cap 41 3/8” Shank
21 Spindle Housing 42 Spring
43 Steel Ball

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DECLARATION OF CONFORMITY