Clarke 3110432 Operating & Maintenance Instructions

14 PIECE AIR TOOL KIT

MODEL NO: CAT232

PART NO: 3110432

OPERATING & MAINTENANCE

INSTRUCTIONS

GC0215

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.

Read this instruction booklet carefully before use.

Wear ear protection.

Wear eye protection.

Wear dust mask

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

CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN

PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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, CO 2 , 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.

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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 0 o

C.

5. Additionally, please keep these instructions in a safe place for future reference.

BEFORE USE

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.

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).

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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

Model Number

Dimensions (L x W x H)

CAT23C Impact

Wrench

180 x 60 x 180 mm

CAT21B Reversible

Ratchet Wrench

154 mm long

Air Inlet Size

Operating Pressure

Air Consumption

No Load Speed

Sound Pressure Level (LpA dB)

Sound Power Level (LwA dB)

Vibration Levels

Drive Size

Max Tightening Torque

Max Bolt Capacity

1/4“BSP (female) 1/4“BSP (female)

90 psi (6.2 bar) 90 psi (6.2 bar)

4.5 cfm at max load 4 cfm at max load

1500 rpm @ 90psi

94 dB(A)

105 dB(A)

10.4 m/s

2

1/2” Square

260 ft/lb +/-10%

5/8” (16mm)

1500 rpm @ 90psi

89.6 dB(A)

101.5 dB(A)

9.13 m/s

2

3/8” Square

50 ft.lb +/-10% n/a

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.

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COMPRESSED AIR REQUIREMENTS

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU

ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF

COMPRESSORS AND COMPRESSED AIR SUPPLY.

• 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.

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OPERATION - IMPACT WRENCH

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.

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.

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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.

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.

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.

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OPERATION

USING THE DIRECTION CONTROL

WARNING: ALWAYS WAIT UNTIL THE DRIVE SHAFT HAS STOPPED ROTATING

BEFORE OPERATING 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.

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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.

Tool runs slowly. Air flows weakly from exhaust.

Tool will not run. Air flows freely from exhaust.

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.

1. Motor parts jammed

with gum/dirt.

2. Regulator in closed

position.

3. General airflow

blocked by dirt.

1. Motor vanes stuck

due to buildup of

foreign material.

1. Examine inlet air filter for

cleanliness.

2. Adjust regulator to open

position.

3. Operate tool in short

bursts.

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

WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE

AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE

PROCEDURES.

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.

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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

1800310

1800305

1800345

1800350

1800355

1800360

CAT37B

CIS12/17

CIS9/32

1 piece 1/2”square drive (metric)

17 piece 1/2”square drive (metric/AF)

32 piece 3/8” & 1/2”square drive (metric/AF)

CIS12/7M 7 piece 1/2”square drive universal joint (metric)

CIS12/7MD 7 piece 1/2”square drive universal joint (deep) metric

CIS12/6H

CIS12/6S

6 piece 1/2”square drive hex key set (metric)

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

6

7

4

5

1

2

3

Housing

Valve Bushing

Reverse Valve

Trigger

Pin

Valve Stem

Air Inlet

8

9

Ball Set

Spring

10 Steel Ball

11 Screen

12 Air Regulator

13 O-Ring

14 Spring

15 Oil Seal

16 Screw

17 Anvil Bushing

18 Anvil (1/2”)

19 Hammer Cage

20 Hammer Pin

21 Hammer Dog

22 Drive Cam

23 Pin

No Description

24 Cylinder

25 Rotor

26 Rotor Blade

27 Front End Plate

28 Ball Bearing

29 Rear End Plate

30 Pin

31 Spring

32 Pin

33 Gasket

34 Rear Cover

35 Washer

36 Screw

37 Rubber Protector

38 Exhaust Deflector

39 Screw

40 Screw

41 Anvil Collar

42 O-Ring

43 Rubber Seal

44 Screw

45 Oil Seal

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PARTS DIAGRAM - RATCHET WRENCH

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PARTS LIST - RATCHET WRENCH

No Description

6

7

4

5

1

2

3

Air Inlet

Handle

Throttle Lever

Pin

Throttle Bushing

Valve - Throttle

O-Ring

8

9

Spring - Throttle

O-Ring

10 Plug - Throttle Valve

11 Bearing Cap

12 Bearing

13 Plate - Front End

14 Pin

15 Rotor

16 Rotor Blade

17 Cylinder

18 Plate - Rear End

19 Bearing

20 Bearing Cap

21 Spindle Housing

No Description

22 Gear

23 Gear Plate

24 Clamp Housing

25 Bearing

26 Ratchet Housing

27 Pin - Lock

28 Spring - Ratchet

29 Button - Reverse

30 Washer

31 Pin

32 Pawl - Ratchet

33 n/a

34 n/a

35 Washer

36 Retaining Ring

37 Bearing

38 Crankshaft

39 Bushing - Drive

40 Yoke - Ratchet

41 3/8” Shank

42 Spring

43 Steel Ball

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DECLARATION OF CONFORMITY

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