Clarke X-Pro CAT198 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1019 ISS 1
½”AIR IMPACT WRENCH
MODEL NO: CAT198
PART NO: 3120515

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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
CAT198 Part no 3120515
Dimensions (L x W x H) 197 x 190 x 68 mm
Weight(s) 2.49 kg
Drive size ½” square
Air Inlet Size ¼”BSP female
Max operating air pressure 90 psi (6.3 bar)
Air Consumption average 6.5 cfm
Max Torque 650 ft/lbs (reverse 670 ft/lbs)
Max No Load Speed 8000 rpm @ 90 psi
Torque at settings 1-4
Forward 1 185 ft/lbs
Forward 2 330 ft/lbs
Forward 3 650 ft/lbs
Reverse 4 670 ft/lbs
Sound Pressure Level (LpA dB) 77 dB(A)
Sound Power Level (LwA dB) 88 dB(A)
Vibration Level 6.096 m/s2(uncertainty factor K= 1.5 m/s2)

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GENERAL SAFETY RULES
THE 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
wrench
4. DO NOT operate where there are flammable liquids or gases.
USE OF COMPRESSED AIR TOOLS
1. Stay alert and use common sense - do not use the wrench when you are
tired or under the influence of alcohol, drugs or medication.
2. ALWAYS wear eye protectors when using the wrench. 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. NEVER use oxygen, CO2, combustible gases or any type of bottled gas as a
source of power for any air tool.
5. DO NOT connect the air supply hose with your finger on the trigger.
6. DO NOT exceed the maximum pressure of 90 psi / 6.2 bar.
7. Keep the air supply hose away from heat, oil and sharp edges.
8. DO NOT fit any air tool to a stand or clamping device that may damage it.
9. 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 tool will be left unattended.
• Moving to another work area.
13. NEVER use the tool if it is defective or operating abnormally.
14. Avoid damaging the tool by applying excessive force.
15. ALWAYS maintain the tool with care. Keep it clean 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 air 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. NEVER carry the wrench by the air hose.
20. NEVER carry the wrench with your finger on the trigger.
21. When not in use the wrench should be disconnected from the air supply
and stored in a dry place out of reach of children.
IMPACT WRENCH SAFETY INSTRUCTIONS
1. ALWAYS use the 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 components 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. 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. 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 air 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 air 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 air tool.
Never exceed the maximum operating pressure. It is recommended that air
pressure does not exceed 90 psi (6.2 Bar) 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
1½”Square Drive shaft 5 Extension bar
2 Trigger 6 Air exhaust
3 Allen key 7 Direction/Speed Control
4 Inlet adaptor 8 Airline Inlet

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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. 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 connector or
via the hose at the nearest
connection to the air supply.
5. Connect a suitable hose as shown
or use the snap connector
supplied to connect directly to the
hose.
6. Connect the other end of the hose to the compressor.
7. Turn on the air supply and check for air leaks. Rectify any found before
proceeding.
• PTFE tape may be useful for sealing threaded connections.
8. 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.
You can fit a whip hose with a quick fit coupling if required, available from
your CLARKE dealer.
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 ½”
square drive shaft as shown.
• If required, the extension bar
can be used when the nut is in
an enclosed space.
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 WRENCHES
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 or bolt 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/bolts.
4. Soak rusted nuts in penetrating oil, and break any rust seal before twisting
off with the wrench.
TIGHTENING A NUT/BOLT
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 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 wrench.
3. Shut down the compressor at the end of the work session.
WARNING: ENSURE THAT THE CORRECT SOCKET IS BEING USED FOR THE
NUTS 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 airline 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.
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 effect the operation and efficiency of
any 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. Air 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. Air 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. Air 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 air 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
environment.
When storing, replace the blanking plug on the airline inlet once the airline has
been disconnected.
Avoid storing the wrench 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:
CIS12/11 11 piece 1/2” Metric Impact Socket Set part no 3110437
CIS12/17 17 piece 1/2” A/F Deep Impact Socket Set part no 1800310
CIS12/10 1/2” Metric 6 point Impact Socket Set part no 3110875
CIS12/3M 3pc 1/2” drive non-slip socket set part no 1700732
CIS12/6SB 6-piece impact Spline socket set part no 1700726
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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DECLARATION OF CONFORMITY

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COMPONENT PARTS LIST
No Description No Description
1 Main housing 22 Gasket
2 O-ring 23 Front housing
3Trigger 24Greasecap
4Bolt 25Gasket
5 E-clip 26 O-ring
6Bearing 27Switch
7 Rear plate 28 Spring
8 Cylinder 29 Steel ball
9 Bolt 30 O-ring
10 Rotor 31 Rear cover
11 Spring 32 Set screw
12 Rotor blade 33 Exhaust deflector
13 Front plate 34 Cushion
14 Bearing 35 Bolt
15 Hammer cage 36 Circlip
16 Hammer dog 37 Spacer
17 Hammer pin 38 Oil seal
18 Anvil 39 Tilt valve
19 O-ring 40 Spring
20 Retainer ring 41 O-ring
21 Bushing 42 Air inlet
43 Extension bar

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COMPONENT PARTS DIAGRAM