Clarke CAT 48 Impact Wrench Operating & Maintenance Instructions

3/4”(20mm)
HEAVY DUTY IMPACT WRENCH
MODEL - CAT 48
OPERATING & MAINTENANCE
INSTRUCTIONS
0805
HAND-ARM VIBRATION
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 declaration on page 7.
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/s2 are considered hazardous when used for prolonged periods. A
tool with a vibration value of 2.8 m/s2 may be used for up to 8 hours (cumulative) per day,
whereas a tool with a value of 11.2 m/s2 may 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 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.
2
Please read these instructions carefully before operating the tool
Thank you for purchasing this CLARKE Heavy Duty Impact Wrench, designed for
heavy automotive and industrial use, and incorporating adjustable power settings,
forward and reverse action and a twin hammer impact mechanism.
Before using the wrench, please read this leaflet 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 it giving long and satisfactory service.
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 effect your statutory rights.
SPECIFICATIONS
Drive Size ................................................................. 3/4” square
Max. Torque ............................................................ 500lbft
Air Inlet .................................................................... 1/4" BSP
Min. Hose Size (ID) .................................................. 8mm (5/16")
Ave. Air Consumption ............................................ 7.5 CFM
Air Pressure Max. .................................................... 90 PSI (6.2 BAR)
Net Weight .............................................................. 5 kg
Vibration Level* ...................................................... 16.49m/s2*
Sound Pressure Level** .......................................... 107dBA**
*
Please refer to ‘Hand Arm Vibration’ on Page 2. The total, cumulative time that
this tool should be used, per day, should be measured in minutes .
Declared vibration emmission value in accordance with EN12096
Measured vibration emmission value - a: .............................. 16.49m/s2
Uncertainty value - K: ............................................................... 3.20m/s2
Highest measured reading in a single plane .............................. 16.45m/s2
Values determined according to EN28622-2
** Sound Pressure levels were determined when tightening a 20mm bolt, in a
horizontal plane, to 500lbft.
Levels may vary depending upon conditions of use. A risk assessment should
be carried out, on site, to determine actual levels and appropriate measures
taken to avoid damage to hearing.
3
SAFETY PRECAUTIONS
IMPORTANT
Failure to follow these precautions could result in personal injury, and/or
damage to property.
1.
ALWAYS wear BS approved impact resistant safety goggles. (Eye glasses are
NOT safety glasses).
2.
ALWAYS wear face or dust mask (where dust is created).
3.
ALWAYS wear BS approved Ear Defenders, as considerable noise is generated,
depending upon application. (see specifications)
4.
ALWAYS disconnect the tool when not in use, before changing accessories
and before carrying out any maintenance
5.
ALWAYS have trigger in the OFF position when connecting to an air supply.
6.
ALWAYS keep a safe distance between yourself and other people when using
the tool.
7.
ALWAYS maintain the tool with care. Keep it clean for best and safest
performance.
8.
DO NOT wear ill fitting clothing, remove watches and rings.
9.
DO NOT locate Quick Change couplings at the tool. They add weight and
could fail due to vibration.
10. DO NOT over-reach. Keep your proper footing and balance at all times.
11. DO NOT force or misuse the tool. It will do a better and safer job at the rate for
which it was designed.
12. 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 weak or worn condition before use, and ensure that
all connections are secure.
13. DO NOT exceed 90 psi at the tool.
14. DO NOT use hand sockets, as these could shatter with serious consequences.
Use only impact wrench sockets, which MUST be in good condition.
15. DO NOT use extension bars unless absolutely necessary - use deep sockets
when possible.
16. NEVER operate the tool unless it is attached to the work - the speed of rotation
could cause the socket to be thrown from the wrench
17. DO NOT modify the tool in any way.
18. DO NOT allow anyone to use the tool unless they are physically capable of
handling its’ bulk weight and power.
4
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, 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 below. 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).
Filter / Regulator
Fig.1
Airline Hose
Air
Supply
Minimum hose diameter should be
8mm (5/16") ID., and fittings should
have the same inside dimensions.
Regulator
Filter
Airline Hose
OPERATION
Select an appropriate impact socket, which must be in good condition, and fits
the tool shank and nut closely. (NEVER use standard hand sockets)
Forward and Reverse is obtained by pushing the lever, on the side of the tool, to
the ‘F’ or ‘R’ position.
Tool power is adjusted by turning the knob, at the base of the tool, to one of the
settings etched in the knob. The lower the number, the lower the power setting.
Turn the 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.
Start the tool, in the FORWARD position, and gradually turn the 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 setting.
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.
For additional power on disassembly work, turn the regulator to its highest setting.
This tool is rated at 3/4" 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.
Soak rusted nuts in penetrating oil, and break rust seal before turning off with the tool.
IMPORTANT: Where the torque setting is critical, the final tightening of nuts or bolts,
must be by hand using a properly calibrated torque wrench.
5
MAINTENANCE
Daily
1. Before use, drain water from air tank, air line and compressor.
2. If no line Lubricator is used, ensure that oil is applied to the tool (see below).
Weekly
Clean the air inlet filter screen (within parts list item 31).
Monthly
Oil the Hammer mechanism at least once per month, by removing the hex. socket
screw in the side of the tool, and injecting a few drops of oil, (SAE30).
For lubricating the air motor, an air line lubricator should be used, with 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 run the tool.
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 disassembled, thoroughly cleaned, dried and reassembled.
If the tool runs erratically or becomes inefficient, and the air supply is sound,
dismantle the air motor and hammer mechanism and replace worn or damaged
parts, or take the tool to your CLARKE dealer.
Keep the tool clean at all times, and ensure that the hex. socket screws securing
the hammer case remain tight.
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
Spare Parts Department on 020 8988 7400
DISPOSAL
When disposing of this product, ensure it is disposed of according to all l.ocal
ordinances
SPARE PARTS AND SERVICING
Contact your nearest dealer, or CLARKE International, on one of the following numbers.
PARTS & SERVICE - 020 8988 7400
PARTS & SERVICE E-Mail: Parts(or Service)@clarkeinternational.com
6
PARTS LIST
Item Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Protecting Rubber
Seal
Housing
Screw
Anvil Bushing
Anvil Collar
O-ring
Spacer
Anvil
Hammer Pin
Hammer Cage
Hammer
Cam
Seal
O-ring
Front Plate
Rotor Blade
Rotor
Cylinder
Washer
Ball Bearing
Rear Plate
Rear Cover
Washer
Screw
Screw
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
6
1
1
1
1
1
1
4
4
3
Part No.
Item Description
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
28-0030
00-4205
28-0001
00-0614
28-0014
28-0016
00-4118
28-0017
28-0015
28-0019
28-0018
28-0020
28-0021
00-4206
00-4108
28-0022
28-0024
28-0023
28-0025
28-0034
00-2312
28-0026
28-0028
00-1803
00-0119
00-0110
7
Rear Rubber
Washer
O-ring
Valve Sleeve
Reverse Valve
Rear Gasket
O-ring
Air Regulator
Screw
Exhaust Deflector
Pin
Spring
Screw
Trigger
Pin
Pin
Valve Stem
Spring
Hose Adapter
Ball Bearing
O-ring
Qty
1
3
3
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
Part No.
28-0031
00-1802
00-4111
28-0002
28-0003
28-0027
00-4106
28-0008
00-0802
28-0012
28-0009
28-1031
00-0610
28-0004
00-3301
00-3305
28-0005
28-0011
25-1010
00-2313
00-4114