Clarke CAT55 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC07/14
AIR RATCHET WRENCH
MODEL NO: CAT55
PART NO: 3120500

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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.
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 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 CAT55 ratchet wrench is 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 Trigger
2 Speed Control 5 Square Drive Shaft
3 Air 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 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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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 air 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 Part No Description No Part No Description
1 106201 Inlet Bushing 21 106221-1AA0 Gear Plate
2 106202 Handle 21P 106221-AAA0 Pin
3 103127 Throttle Lever 22 106222 Clamp-Housing
4 P-0030-220 Pin 23 106223-1AA0 Bushing
5 106505-1AA0 Bushing 24 106224 Ratchet
6 106206-1AA0 Valve 25 106225-1JB0 Pin Lock
7 0-0300-180 O-Ring 26 106226-1AA0 Spring
8 106308-1AA0 Spring 27 106227-1JB0 Button
9 0-0700-200 O-Ring 28 106228-1GR0 Pin
10 106310-1AA0 Plug 29 106229-1GV0 Pawl
11 0625-ZZ0A Ball Bearing 30 106230-1JB0 1/4” Shank
12 103416-1DA0 Rear End Plate 31 106231-1AA0 Spring
13 P-0025-060 Pin 32 106232-1AA0 Steel Ball
14 106214-1GV0 Rotor 33 106223-1JB0 Washer
15 103418-1GR0 Rotor Blade 34 R-R235 Circlip
16 103421 Cylinder 35 0910-HK0 Bearing
17 106217-DA0 Front End Plate 36 106236-1GR0 Crankshaft
18 0608-ZZ0A Ball Bearing 37 106237-1TT0 Drive Bush
19 106219-1AA0 Spindle 38 106238-2JB0 Yoke
20 106220-1TT0 Gear

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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 CAT55
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption Average 3 cfm
Max No Load Speed 250 rpm +/-10%
Air Inlet Size 1/4“BSP Female
Sound Pressure Level (LpA dB) 90.66 dB(A)
Sound Power Level (LwA dB) 101.15 dB(A)
Vibration Levels determined
according to EN28622-2 6.13 m/s2
(uncertainty factor K= 2.45m/s2)
Highest measured in a single plane-6.4m/s2
Weight 1. kg
Drive Type 1/4” Square
Max Torque 30 ft/lb +/-10%

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DECLARATION OF CONFORMITY