Clarke CAT141 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0220 - rev 2
AIR IMPACT WRENCH
MODEL NO: CAT141 & 142
PART NO: 3120155 / 3120156

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INTRODUCTION
hank you for purchasing this CLARKE Impact Wrench. The CAT141 and CAT142
are identical wrenches, the CAT142 being supplied in a moulded plastic
storage case which contains the following:
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. 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. The following safety symbols are to be found on
the tool.
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.
• 1 x Mini-Oiler • 1 x Extension Bar
• 1 x Hex Key • Snap Connector fitting
• Oil Bottle • 10 Impact Sockets, (9, 10, 11, 13,
14, 17, 19, 22, 24 & 27mm sizes)
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. Keep the air supply hose away from heat, oil and sharp edges.
8. Do not fit the tool to any stand or clamping device that may damage it.
9. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
10. Do not use the tool for any purpose than that described in this manual.
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 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.
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.
9. Always disconnect from the air supply when changing sockets or when the
wrench is not required for immediate use in order to avoid accidental
starting.

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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.
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.
Please keep these instructions in a safe place for future reference.
OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Square Drive 3 Direction/Speed Control
2 Trigger 4 Airline Inlet

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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 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 COMPRESSED AIR SUPPLY.

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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.
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 airline connector 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. 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.
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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OPERATION
Forward/Reverse rotation is selected by pushing the combined Forward/
Reverse knob/power regulator in the direction shown by the arrow on the
back of the wrench.
1. For normal tightening, the wrench
should be operated in the forward
(F) direction at position 1, 2 or 3.
2. For loosening, the wrench should
be operated in the reverse (R)
direction.
FITTING THE IMPACT SOCKET
1. Select the impact socket you
require, which must be in good
condition and fit the tool exactly.
2. Push the socket onto the square
drive shaft 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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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 tool to
one of the 3 settings available.
(Setting 1-Low, 3 -High)
• These numbers are only for
reference and do not denote a
specific amount of power.
For maximum power when removing
stubborn nuts, turn the impact wrench
to its highest setting.
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.

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MAINTENANCE
DAILY
1. Before use, drain water from the airline filter and compressor.
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, or at the start of the working day.
3. Keep the body of the tool clean and free from debris.
WEEKLY
• Check the air inlet screen filter
for blockage and clean out if
necessary.
CLEANING
1. Grit or gum deposits in the tool
may reduce efficiency and cause
the tool to run erratically. This
condition can be corrected by
cleaning the air strainer and
flushing out the tool with gum
solvent oil.
2. Failing this, the tool should be disassembled, thoroughly cleaned, dried
and reassembled.
3. The tool may be dismantled by removing the rear cover using the hex key
supplied prior to replacing any worn or damaged parts. You may prefer to
take the tool to your Clarke dealer if internal maintenance is required.
4. While is a dismantled state, it may be desirable to grease the hammer
mechanism and applying a small amount of good quality bearing grease.
• This may be better left to your Clarke dealer.
• A hex key is provided for removing the end cover from the wrench.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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TROUBLESHOOTING
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.
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. Throttle O-rings
damaged or ill-fitting
in seat.
1. Return to Clarke dealer
for repair.

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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. Store the tool safely in its box in a dry, secure
environment.
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 CAT141/CAT142
Part Number(s) 3120155 / 3120156
Min. Hose Size (ID) 1/4” BSP
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption 18 cfm (max @90psi) average 6.5 cfm
Drive size 1/2” Square
Max No Load Speed 7000 rpm @ 90psi
Max Torque 350 ft/lb
Air Inlet Size 1/4“BSP Female
Sound Pressure Level (LpA dB) 87 dB(A)
Sound Power Level (LwA dB) 98 dB(A)
Vibration Levels 4.35 m/s2 (uncertainty factor K= 1.5m/s2)
Weight(s) 2.2 kg (CAT141)
4.26 kg complete (CAT142)
Wrench Dimensions (L x W x H) 198 x 190 x 67 mm

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PARTS LIST
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 the Clarke International
Service Department.
No Description No Description
1 Main Housing 21 Trigger
2 Nose Bushing 22 Spring
3 Square Drive 23 Trigger Sleeve
4 Hammer Cage 24 Roll Pin
5 Hammer 25 Valve Sleeve
6HammerPin 26ValveStem
7 Bearing 27 Spacer
8 Oil Seal 28 Bolt
9 Front Plate 29 Set PIn
10 Set Pin 30 Spring
11 Cylinder 31 Forward/Reverse Switch
12 Set Pin 32 Oil Seal
13 Rotor 33 Pin
14 Rotor Blade 34 Pin Cover
15 Rear Plate 35 Spring
16 Gasket 36 O-Ring
17 Ringpiece 37 Exhaust Deflector
18 Rear Cover 38 Cushion
19 Washer 39 Air Inlet
20 Socket headed Screw 40 Soft Grip

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PARTS DIAGRAM

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DECLARATION OF CONFORMITY