Clarke X-Pro CAT163 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0917 Issue 2
3/4”HD IMPACT WRENCH
MODEL NO: CAT163
PART NO: 3120177

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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
Dimensions (L x W x H) 235 x 102 x 262
Weight 7.15 kg
Drive size 3/4” square
Min. Hose Size (ID) 8 mm (5/16”)
Air Inlet Size 3/8“BSP Female
Recommended Hose size 13 mm
Operating Pressure 90 psi (6.2 bar)
Air Consumption 40 cfm (max load) (8.5 cfm average)
Max Torque 1800 Nm (1373 Ft.lb)
No Load Speed 4200 rpm @ 90psi
Speed Settings & RPM
Forward/Reverse 1 700
Forward/Reverse 2 3950
Forward/Reverse 3 4200
Sound Pressure Level (LpA dB) 91 dB(A)
Sound Power Level (LwA dB) 102 dB(A)
Vibration Levels 15.5 m/s2 (Uncertainty K = 2.0m/s2)

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GENERAL SAFETY RULES
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:
• Performing any maintenance
• The tool is not in use.
• The tool will be left unattended.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• Moving to another work area.
• Passing the tool to another person.
13. Never use the tool if it is defective or operating abnormally.
14. The tool should be serviced if required by qualified service personnel.
15. Avoid damaging the tool for example by applying excessive force.
16. ALWAYS maintain the tool with care. Keep it clean for the best and safest
performance.
17. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
18. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
19. Do not remove any labels. Damaged labels should be replaced.
20. 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.

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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.
Read this instruction
booklet carefully
before use.
Wear ear protection
Wear eye protection .

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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.
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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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.
• PTFE tape may be useful for
sealing threaded connections.
5. If required, connect an in-line mini oiler to the tool.
• A mini oiler helps to prolong the life of the air tool.
6. 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.
7. 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).
8. Ensure the trigger is NOT depressed when connecting the air line.
• 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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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.
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 ANVIL HAS STOPPED ROTATING BEFORE
OPERATING THE FORWARD/REVERSE BUTTON.

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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.
• 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).
• These numbers are only for
reference and do not denote a
specific amount of power.
2. For maximum power when
removing stubborn nuts, set the
wrench to its highest setting.
3. 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.
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.

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

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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.

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TROUBLESHOOTING
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.
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
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.
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.

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PARTS DIAGRAM

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PARTS LIST
No Description No Description
1 Socket head bolt 29 Nut
2Washer 30Pin
3 Hammer Casing 31 Trigger
4D-Handle 32Pin
5 Socket head bolt 33 Handle Body
6 Gasket 34 Inlet Spring
7 Anvil Bush 35 O-Ring
8 Circlip 36 Air Inlet
9 O-Ring 37 Air Inlet Screen
10 Anvil 38 Inlet Valve
11 Hammer 39 O-Ring
12 Hammer Cage 40 Inlet Valve
13 Hammer Pin 41 O-Ring
14 Gasket 42 Throttle Valve Pin
15 Bearing 43 Inlet Gasket
16 Front End Plate 44 Throttle Bushing
17 Vane 45 Throttle Core
18 Rotor 46 Spring
19 Pin 47 Steel Ball
20 Cylinder 48 O-Ring
21 Pin 49 Direction Switch
22 Rear End Plate 50 Washer
23 Bearing 51 Screw
24 Circlip 52 Gasket
25 Gasket 53 Back Cover
26 Sponge 54 Washer
27 Mesh 55 Socket head bolt
28 Silencer

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DECLARATION OF CONFORMITY