Clarke CAT163 34HD IMPACT WRENCH Instruction Manual

Clarke CAT163 34HD IMPACT WRENCH

INTRODUCTION

Thank you for purchasing this CLARKE Impact 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. Please keep these instructions in a safe place for future reference.

SPECIFICATION

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 AIR POWERED TOOLS

1. Stay alert and use common sense – do not operate the wrench when you are tired or under the influence of alcohol, drugs or medication.
2. Always wear eye protectors when using the tool – Eye protection must provide protection from flying particles/objects 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 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 wrench 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 other 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:
13. Performing any maintenance
14. The tool is not in use.
15. The tool will be left unattended.
16. Moving to another work area.
17. Passing the tool to another person.
18. Never use the tool if it is defective or operating abnormally.
19. The tool should be serviced if required by qualified service personnel.
20. Avoid damaging the tool for example by applying excessive force.
21. ALWAYS maintain the tool with care. Keep it clean for the best and safest performance.
22. Quick change couplings should not be located at the tool. They add weight and could fail due to vibration.
23. Do not force or misuse the tool. It will do a better and safer job at the rate for which it was designed.
24. Do not remove any labels. Damaged labels should be replaced.
25. 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 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 impact wrench. When tightening a nut or bolt, only allow the wrench to impact briefly to avoid overtightening.
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 vehicle 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 to avoid accidental starting
9. Never carry the wrench by the air supply hose.
10. Always use both hands to control the wrench.
11. Always ensure the wrench has stopped before putting it down.

SAFETY SYMBOLS

Please read all of the safety and operating instructions carefully before using this product. The following safety symbols are to be found on the machine.

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.

THE COMPRESSED AIR SUPPLY

AIR SUPPLY 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. SAE 10 oil should be used and the lubricator adjusted to approx 2 drops per minute.
• The minimum hose diameter should be 13mm ID and fittings should have the same internal dimensions.
• 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 unclean air will shorten the life of the tool due to faster wear and is a possible safety hazard.

BEFORE USE

1. Fit the handle as shown using the bolts provided. A hex key is supplied for this purpose.
2. Remove the protective plug from the air inlet port and connect a suitable hose as shown.
3. Connect the other end of the hose to the compressed air supply.
4. Turn on the air supply and check for air leaks. Rectify any found before proceeding.
5. PTFE tape may be useful for sealing threaded connections.
6. If required, connect an in-line mini oiler to the tool.
7. A mini oiler helps to prolong the life of the air tool.
8. 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 airline inlet or via the hose at the nearest connection to the air supply.
9. A gauze filter is fitted within the air inlet. Ensure this filter is always in place and is kept clean. An air line is connected to the adapter, preferably via a quick release coupling (not supplied).
10. Ensure the trigger is NOT depressed when connecting the air line.
11. Your air tool is now ready for use
12. You can fit a whip hose with a quick fit coupling if required (available from your Clarke dealer.)

OPERATION

FITTING AN 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 square drive shaft.

SETTING THE FORWARD/REVERSE ROTATION
Forward/Reverse rotation is selected by pushing the combined Forward/Reverse knob/power regulator in the direction shown by the arrow on the back of the wrench.

1. For normal tightening, the wrench should be operated in the forward (F) direction at position 1, 2 or 3.
2. For loosening, the wrench should be operated in the reverse (R) direction.

OPERATING THE IMPACT WRENCH

1. Locate the socket over the nut to be tightened or loosened.

2. Squeeze the trigger to start and release the trigger switch to stop the wrench.

3. The square drive will continue to rotate very briefly after the trigger has been released.

ADJUSTING THE SPEED

1. To adjust the speed, set the lever to one of the 3 settings available. (Setting 1-Low, 3- High).
2. These numbers are only for reference and do not denote a specific amount of power.
3. For maximum power when removing stubborn nuts, set the wrench to its highest setting.
4. Where the torque setting is critical, the final tightening of nuts or bolts must be done by hand using a 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. 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 proceed to fully undo the wheel nuts.
4. Soak rusted nuts in penetrating oil, and break rust seal before twisting off with the wrench.

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 selector 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 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 are tightened. Ensure the final torque applied to the nuts meets the vehicle manufacturer’s recommendations.c

DISCONNECTING THE AIR SUPPLY

1. Do not disconnect the air supply hose until the air supply has been shut down and the compressed air released.
2. Refer to the compressor instruction manual for the procedure to shut down and release the compressed air.
3. Once the pressure has been released, disconnect the air supply hose from the wrench.

MAINTENANCE

WARNING:
MAKE SURE THAT THE WRENCH IS DISCONNECTED FROM THE AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE PROCEDURES.

Please note that factors other than the tools condition 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.

DAILY

1. Before use, drain water from the air-line and compressor.
2. Lubricate the air tool daily for optimum performance. Use a high quality airline oil either via a lubricator in the air supply system or by placing a few drops into the air inlet immediately before use. This should be carried out regardless of whether or not an in-line lubricator is used.

CLEANING & OVERHAUL

1. If the wrench becomes sluggish and the air supply is of good quality, it may be necessary to replace worn or damaged parts.
2. Grit or gum deposits in the mechanism may eventually reduce efficiency. This condition can be corrected by cleaning the air inlet filter and flushing out the tool with gum solvent oil or an equal mixture of SAE No10 oil and paraffin.
3. Failing this, the tool may be dismantled by unfastening the bolts and removing the rear cover prior to replacing any worn or damaged parts. You may prefer to take the tool to your Clarke dealer if internal maintenance is required.
4. 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.

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 depress the trigger in order to lubricate the internal parts. 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. Avoid storing in a damp environment.

TROUBLESHOOTING

pressure on drill.

2.   Motor parts worn.

| 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.

 | 3. Worn or sticking mechanism due to lack of lubricant.
Tool runs slowly. Air flows weakly from exhaust.| 1.   Motor parts jammed with gum/dirt.

2.   Regulator in closed position.

3.   General airflow blocked by dirt.

| 1.   Examine inlet air filter for cleanliness.

2.   Adjust 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.

ACCESSORIES
A wide range of accessories is available including filter/regulators, lubricators, high-pressure hoses (5 to 50 metres) etc. Contact your CLARKE dealer for further information or CLARKE International Service Department on 01992 565333. Clarke Air Line Oil (part no. 3050825) is available from your CLARKE dealer.

PARTS DIAGRAM

PARTS LIST

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