Clarke X-Pro CAT204 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 - ISS 1
3/4”AIR IMPACT WRENCH
MODEL NO: CAT204
PART NO: 3120521

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INTRODUCTION
Thank you for purchasing this CLARKE Impact Wrench.
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.
Please keep these instructions in a safe place for future reference.
SPECIFICATION
Model Number CAT204
Part Number(s) 3120521
Min. Hose Size (ID) 3/8” (9.5mm)
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption 8.5 cfm
Drive size 3/4” Square
Max No Load Speed 9000 rpm @ 90psi
Max Torque 850 ft/lb (1150 Nm)
Torque settings 1) - 370 ft/lbs
2) - 590 ft/lbs
3) - 850 ft/lbs
4) - in reverse - 880 ft/lbs
Air Inlet Size 1/4“ BSP Female
Sound Pressure Level (LpA dB) 77 dB(A)
Sound Power Level (LwA dB) 88 dB(A)
Vibration Levels 6.096 m/s2(uncertainty factor K= 1.5m/s2)
Weight 2.49 kg
Wrench Dimensions (L x W x H) 197 x 190 x 68 mm

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GENERAL SAFETY RULES
WORK ENVIRONMENT
1. ALWAYS keep the work area clean and tidy.
2. ALWAYS Dress appropriately - Do not wear loose clothing or jewellery. Tie
long hair out of the way.
3. ALWAYS Keep children and visitors away - DO NOT let children handle the
air tool.
4. DO NOT operate the air tool where there are flammable liquids or gases.
USE OF POWER TOOLS
1. ALWAYS 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. DO NOT 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. ALWAYS 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. ALWAYS 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.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• The air tool will be left unattended.
• Moving to another work area.
13. DO NOT use the tool if it is defective or operating abnormally.
14. DO NOT damage the air tool by applying excessive force.
15. DO NOT maintain the tool with care for the best and safest performance.
16. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
17. DO NOT force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
18. 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.
19. DO NOT carry the air tool by the air hose.
20. DO NOT carry the tool with your finger on the trigger.
21. When not in use the air tool must be disconnected from the air supply and
stored in a dry place out of the reach of children.
IMPACT WRENCH SAFETY INSTRUCTIONS
1. ALWAYS use the impact wrench as 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 wrench. When tightening a nut or bolt,
only allow the wrench to impact briefly to avoid over tightening.
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. 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.
9. ALWAYS use both hands to control the impact wrench.
10. ALWAYS ensure the wrench has stopped before putting it down after use.

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COMPRESSED AIR REQUIREMENTS
A typical air line layout is shown below. 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.
Use only clean, dry, regulated compressed air as a power source.
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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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. For best 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.
PRODUCT OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 3/4”Square Drive 5 Direction/Speed Control
2 Trigger 6 Air exhaust
3 Allen key 7 Airline Inlet
4 Inlet adaptor

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BEFORE USE
NOTE: Ensure the compressor is turned off.
1. Remove the plastic blanking plug from the air inlet connection.
2. Pour 2-3 drops of CLARKE airline oil into the oil filling port. This should be
done regardless of whether or not a lubricated air supply is to be used.
3. If required, connect an in-line mini oiler to the tool.
• A mini oiler helps to prolong the life of any air tool.
4. Connect a suitable hose as shown
or use the snap connector
supplied to connect directly to the
hose.
5. Connect the other end of the hose
to the compressor.
6. Turn on the air supply and check
for air leaks. Rectify any found
before proceeding.
• PTFE tape may be useful for
sealing threaded connections.
7. If using a mini oiler, place a sheet of paper next the exhaust port and hold
the throttle open for approximately 30 seconds. The oil volume is correctly
set when a light stain of oil can be seen on the paper. Excessive oil should
be avoided.
Your impact wrench is now ready for 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 SUPPLY.

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OPERATION
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 3/4”
square drive shaft as shown.
ADJUSTING THE DIRECTION AND SPEED
1. To adjust the speed, turn the switch
slowly forward until the desired
output is achieved.
• Setting 1 (small dot) is the least
amount of power while setting 3
(large dot) is the most powerful.
• The wrench operates at
maximum power in reverse. This
setting is for releasing threaded
fasteners.
NOTE: Where the torque setting is critical, the final tightening must be by
hand using a correctly calibrated torque wrench.
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR
USE WITH IMPACT TOOLS.
WARNING: WAIT UNTIL THE WRENCH HAS STOPPED ROTATING BEFORE
OPERATING THE FORWARD/REVERSE SWITCH.

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LOOSENING A WHEEL NUT/BOLT
1. Remove any wheel trim, before selecting the appropriate socket and
placing firmly on the square drive of the wrench.
2. With the control switch in the REVERSE running position (anti-clockwise) and
holding the wrench firmly in BOTH HANDS, squeeze the trigger. The nut will
be impacted repeatedly until it is loosened. IMPORTANT! Release the trigger
as soon as 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 fully undo the wheel nuts.
4. Soak rusted nuts in penetrating oil, and break any rust seal before twisting
off with the wrench.
TIGHTENING A NUT
1. Start the nut/bolt by hand, ensuring it is not cross threaded, then with the
appropriate socket installed on the wrench, place it on the nut/bolt.
2. With the selector switch in the clockwise (forward running) position and
holding the wrench firmly in BOTH HANDS, pull the trigger.
3. Run each nut/bolt up in turn until it is ‘nipped’ up only - do not tighten.
When all nuts/bolts are nipped up, tighten progressively by pulling the
trigger fully and allowing the action to operate briefly 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/bolts are tightened. Ensure the final torque applied to the nuts/bolts
meets the vehicle manufacturer’s recommendations.
For torque values, see specification on page 2.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air hose until the supply is isolated at a shut-off
valve.
2. Once the pressure has been isolated, disconnect the air supply hose from
the air tool.
3. Shut down the compressor at the end of the work session.
WARNING: ENSURE THAT THE CORRECT SOCKET IS BEING USED FOR THE
NUTS/BOLTS ON YOUR PARTICULAR VEHICLE. USING AN INCORRECT
SOCKET SIZE IS LIKELY TO DAMAGE THE HEADS OF THE BOLTS/NUTS.

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MAINTENANCE
DAILY
1. Before use, drain water from the airline filter and compressor.
2. If no line lubricator or mini oiler is used, ensure that oil is applied to the tool
on a daily basis through the air inlet connection. Run a few drops of oil
through the tool before use. 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. After this you can operate the tool.
3. This procedure should be repeated after every two to three hours of use, or
at the start of the working day.
4. Keep the body of the tool clean and free from debris.
WEEKLY
1. Check the air inlet screen filter for
blockage and clean if necessary.
CLEANING & OVERHAUL
1. Grit or gum deposits in the tool
may reduce efficiency.
2. 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.
3. If the tool still 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.
4. The air tool may be dismantled by unfastening the bolts and removing the
rear cover prior to replacing any worn or damaged parts.
5. 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.
WARNING: MAKE SURE THAT THE WRENCH IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

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TROUBLESHOOTING
PERFORMANCE
Please note that outside factors may affect the operation and efficiency of
the air tool.
These include reduced compressor output, excessive drain on the airline,
moisture ingress, restrictions in the air-line such as the use of connectors of
incorrect size or poor condition which will reduce the air supply.
Your air tool has been designed to give long & 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 and clean if
necessary. 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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Any major servicing and repairs should be carried out by your local CLARKE
dealer or a qualified service technician.
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
place.
When not in use, disconnect from the air supply, clean and store in a safe, dry
place. When storing, replace the blanking plug to the airline inlet.
Avoid storing the tool where the temperature is below 0oC.
ACCESSORIES
A wide range of accessories is available including filter/regulators, lubricators,
high-pressure hoses (5 to 50 metres) etc.
**CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
SUITABLE CLARKE IMPACT SOCKET SETS INCLUDE:
CIS19/9M 8 piece 3/4” Metric Impact Socket Set part no 1800320
CIS19/9S 9 piece 3/4” A/F Impact Spline socket Set part no 1700725
CIS19/5S 5-piece 3/4” Impact Spline socket set part no 1700724
Contact your CLARKE dealer for further information or the CLARKE
International Service Department.
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 affect your statutory rights.

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DECLARATION OF CONFORMITY

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COMPONENT PARTS LIST
No Description No Description
1 Hammer case 21 Bearing
2 Rubber gasket 22 Rubber gasket
3 Anvil bushing 23 O-ring
4 Circlip 24 Switch
5 O-ring 25 Spring
6 Anvil 26 Steel ball
7 Hammer 27 O-ring
8 Hammer cage 28 Back cover
9 Hammer pin 29 Fastening screw
10 Trigger 30 Inlet gasket
11 Pin 31 O-ring
12 Handle 32 Rubber gasket
13 Pin 33 Inlet valve
14 Bearing 34 Inlet spring
15 Front end plate 35 Plastic cover
16 Pin 36 O-ring
17 Cylinder 37 Air inlet
18 Rotor 38 Air inlet screen
19 Vane 39 Silencer fabric
20 Rear end plate

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COMPONENT PARTS DIAGRAM