Clarke CAT134 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC01/14
AIR RATCHET WRENCH
MODEL NO: CAT134 & CAT135
PART NO: 3120148 & 3120149

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INTRODUCTION
Thank you for purchasing this CLARKE Air Ratchet 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. The following safety symbols are to be found on the machine.
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

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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 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. Ear
protectors should also be worn.
3. Do not overreach - Keep proper footing and balance at all times.
4. Never use oxygen, CO2, combustible gases or 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. Do not exceed the maximum pressure for the tool of 90 psi / 6.2 bar.
7. Check 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 the 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.
• Passing the tool to another person.
13. Never use the tool if it is defective or operating abnormally.
14. This tool should be serviced at regular intervals by qualified service
personnel.
15. Avoid damaging the tool for example by applying excessive force of any
kind.
16. Always maintain the tool with care. Keep it clean for the best and safest
performance.
17. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
18. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
19. Do not remove any labels. Damaged labels should be replaced.
20. 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.
TRANSPORT & STORAGE
1. Never carry the tool by the air hose.
2. Never carry the tool with your finger on the trigger.
3. When not in use the tool must 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 where the temperature is below 0oC.

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OVERVIEW
The CAT134 and CAT135 ratchet wrenches are ideally suited to quick removal
and installation of nuts, bolts, and other fasteners where space is limited.
NO DESCRIPTION NO DESCRIPTION
1 Forward/Reverse Switch 4 Speed Control
2 Adjustable Exhaust Deflector 5 Trigger
3 Air Inlet 6 Square Drive Shaft

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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. clarke airline oil should
be used, and the lubricator adjusted to approx 2 drops per minute.
• For optimum performance it is recommended that a minimum 3/8”
ID hose is used.
• 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 dirty 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 A COMPRESSED AIR SUPPLY.

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BEFORE USE
CONNECTING THE AIRLINE
NOTE: Ensure the air supply 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 air tool. Read the
instructions supplied with the mini-oiler before use.
2. If a mini-oiler is not being used, insert a few drops of oil into the tool through
the air inlet before use.
3. Connect a suitable hose as shown.
4. Connect the other end of the hose
to the compressed air supply.
5. Turn on the air supply and check
for air leaks.
• Rectify any found before
proceeding. PTFE tape may be
useful for sealing threaded
connections.
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).
ACCESSORIES
A wide range of accessories is available including filter/regulators, lubricators,
high-pressure hoses (5 to 50 metres) etc.
• Contact your Clarke dealer or the Clarke International Service
Department for further information.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND A COMPRESSED AIR SUPPLY.

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OPERATION
USING THE DIRECTION CONTROL
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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SETTING THE SPEED
1. Set the tool speed by rotating the
control to one of the four settings.
• The graduations on the speed
control indicate the speed
setting when aligned with the
reference mark on the air inlet.
• Speeds available are: 45, 85,
140 or 180 rpm (+/-10%).
NOTE: When critical torque values
are not required, turn the nut
or bolt until it is snug - slightly tighter if gaskets are used between
surfaces.
Where torque settings are critical, the final tightening of nuts or bolts must be
by hand, using a calibrated torque wrench.
SETTING THE EXHAUST DEFLECTOR
The direction of the exhaust air
leaving the tool can be adjusted by
rotating the exhaust deflector.
Twist the exhaust deflector sleeve to
direct the air as required to deflect air
away from the workpiece or operator.
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. Refer to the compressor instruction manual for the procedure to shut down
and vent the compressed air.
3. Once the pressure has been released, disconnect the air supply hose from
the air tool.
4. Store the tool safely in its box in a dry, secure environment.

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MAINTENANCE
DAILY
1. Before use, drain water from the compressed air supply.
2. Pour a few drops of Clarke air-line oil, into the tool 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
1. Check the air inlet screen filter for
blockage and clean if necessary.
CLEANING
1. Keep the body of the tool clean
and free from debris.
2. 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. This is better
left to your Clarke dealer.
3. 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.
4. Clean the air inlet filter screen inside the airl inlet.
5. 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 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 AIR TOOL IS DISCONNECTED FROM THE
COMPRESSED AIR SUPPLY BEFORE STARTING ANY CLEANING, OR
MAINTENANCE PROCEDURES.

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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.
**Clarke Air Line Oil (part no. 3050825) is available from your Clarke dealer.
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
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 & store in a safe, dry place.
PARTS DIAGRAM

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PARTS LIST
No Description No Description
1 Housing 29 Front Plate
2 Valve Stem 30 Bearing
3 Trigger 31 Washer
4 Trigger Pin 32 Thread Ring Gear
5 Housing Cover 33 Idler Gear
6 Soft Grip - Upper 34 Gear Pin
7 Soft Grip - Lower 35 Gear Plate
8 Valve Seat 36 Clamp Nut
9 Throttle Valve 37 Ring Gear
10 Valve Spring 38 Bushing
11 Screw Cap 39 Crankshaft
12 O-Ring 40 Drive Bushing
13 Air Regulator 41 Ratchet Housing
14 Set Plate 42 Ratchet Yoke
15 O-Ring 43 Forward/Reverse Switch
16 Set Plate 44 Sleeve
17 Gasket 45 Spring
18 Air Inlet 46 Washer
19 Screw 47 3/8” Ratchet Head (CAT134)
20 O-Ring 1/2” Ratchet Head (CAT135)
21 Exhaust Deflector 48 Pin
22 Bearing Cap 49 Ratchet Pawl
23 Bearing 50 Thrust Washer
24 Rear Plate 51 Retainer Spring
25 Rotor 52 Spring
26 Rotor Blade 53 Steel Ball
27 Cylinder 54 Spring
28 Pin 55 Steel Ball

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Motor parts worn.
2. Worn or sticking
mechanism due to
lack of lubricant.
1. Return to Clarke dealer
for repair.
2. 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. Air-line regulator in
closed position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
blockage. Drip a few
drops of air tool lubricat-
ing oil into air inlet.
2. Adjust in-line 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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SPECIFICATION
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 CAT134 CAT135
Part Number 3120148 3120149
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption 16 cfm (max). Average 5 cfm (CAT134 / 4.5
cfm -CAT135
Max No Load Speed 180 rpm +/-10%
Air Inlet Size 1/4“ BSP Female
Sound Pressure Level (LpA dB) 87 dB(A)
Sound Power Level (LwA dB) 98 dB(A)
Uncertainty Factor K=3
Vibration Levels 4.35 m/s2 (uncertainty factor K= 1.5m/s2)
Weight 1.2 kg 1.2 kg
Drive Type 1/2” Square 3/8” Square
Max Torque 60 ft/lb +/-10%
Speed Settings (rpm) 180 +/-10%
140 +/-10%
85 +/-10%
45 +/-10%

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DECLARATION OF CONFORMITY