3/4”AIR IMPACT WRENCH
MODEL NO: CAT204
PART NO: 3120521
OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 - ISS 1
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
Part Number(s)
Min. Hose Size (ID)
Max Operating Pressure
Air Consumption
Drive size
CAT204
3120521
3/8” (9.5mm)
90 psi (6.2 bar)
8.5 cfm
3/4” Square
Max No Load Speed
Max Torque
Torque settings
9000 rpm @ 90psi
850 ft/lb (1150 Nm)
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)
Vibration Levels
88 dB(A)
6.096 m/s
2
(uncertainty factor K= 1.5m/s
2
)
Weight 2.49 kg
Wrench Dimensions (L x W x H) 197 x 190 x 68 mm
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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. 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, CO 2 , 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.
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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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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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.
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.
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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
1 3/4”Square Drive
2 Trigger
3 Allen key
4 Inlet adaptor
NO DESCRIPTION
5
6
7
Direction/Speed Control
Air exhaust
Airline Inlet
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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 SUPPLY.
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.
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OPERATION
FITTING THE IMPACT SOCKET
WARNING: NEVER USE STANDARD SOCKETS. THESE MAY SHATTER WITH
SERIOUS CONSEQUENCES. ONLY USE IMPACT SOCKETS DESIGNED FOR
USE WITH IMPACT TOOLS.
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: 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.
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.
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.
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MAINTENANCE
WARNING: MAKE SURE THAT THE WRENCH IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.
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 airline 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.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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.
Tool will not shut off.
1. Motor parts worn.
2. Worn or sticking
mechanism due to
lack of lubricant.
1. Motor parts jammed
with gum/dirt.
2. Air-line regulator in
closed position.
3. General airflow
blocked by dirt.
1. Motor vanes stuck
due to buildup of
foreign material.
1. Return to CLARKE dealer
for repair.
2. Drip air tool lubricating
oil into air inlet. Allow oil
to soak moving parts
before using.
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.
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.
1. Throttle O-rings
damaged or ill-fitting
in seat.
1. Return to CLARKE dealer
for repair.
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.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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 0 o
C.
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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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
DECLARATION OF CONFORMITY
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COMPONENT PARTS LIST
No Description
6
7
4
5
1
2
3
Hammer case
Rubber gasket
Anvil bushing
Circlip
O-ring
Anvil
Hammer
8
9
Hammer cage
Hammer pin
10 Trigger
11 Pin
12 Handle
13 Pin
14 Bearing
15 Front end plate
16 Pin
17 Cylinder
18 Rotor
19 Vane
20 Rear end plate
No Description
21 Bearing
22 Rubber gasket
23 O-ring
24 Switch
25 Spring
26 Steel ball
27 O-ring
28 Back cover
29 Fastening screw
30 Inlet gasket
31 O-ring
32 Rubber gasket
33 Inlet valve
34 Inlet spring
35 Plastic cover
36 O-ring
37 Air inlet
38 Air inlet screen
39 Silencer fabric
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COMPONENT PARTS DIAGRAM
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