Clarke CCIW160 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL 1021 ISS 2
18V CORDLESS IMPACT WRENCH
MODEL NO: CCIW160
PART NO: 4500658

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INTRODUCTION
Thank you for purchasing this CLARKE Cordless 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.
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.
SAFETY SYMBOLS
The full technical specification of the battery charger is printed on a label on
the charger. The meanings of the markings and symbols are shown below
Please keep these instructions in a safe place for future reference.
Read instruction
manual before use
Suitable for indoor use
only
Wear eye protection
when using this
product.
Maximum Temperature
(battery pack only)
Class 2 Double
Insulated
Do not Incinerate
(battery pack only)
WEEE directive
compliance required
for Lithium-Ion
batteries.
Do not immerse in
water

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SAFETY PRECAUTIONS
WORK ENVIRONMENT
1. Keep the work area clean and tidy and free from trip hazards.
2. DO NOT wear loose clothing or jewellery. Tie long hair out of the way.
3. If wearing gloves, make sure that there is no frayed material that could
catch in rotating parts.
4. Keep children and visitors away - DO NOT let children handle the wrench.
5. DO NOT use in damp or wet conditions. Keep the work area well lit. DO
NOT use where a risk of fire or explosion is present.
6. Although the wrench may be used outdoors, DO NOT leave it exposed to
the elements. Avoid direct sunlight, direct heat, rain/moisture etc.
7. ALWAYS keep body and clothing dry. Never work in damp area without
adequate insulation against electric shock.
8. ALWAYS store this product in a dry, secure place out of reach of children or
untrained users.
9. NEVER over-reach. Keep proper footing and balance at all times and
adopt a comfortable, well balanced working position for ongoing work.
GENERAL USE
1. This product vibrates during use. Vibration may be harmful to your hands or
arms. Stop using the wrench if discomfort, a tingling feeling or pain occurs
and seek medical advice before resuming use.
2. ALWAYS use ear defenders for prolonged work. Exposure to high noise
levels can cause permanent hearing problems.
3. ALWAYS wear impact resistant eye protection in case of flying projectiles.
4. ALWAYS stay alert and use common sense - DO NOT use this product when
you are tired or under the influence of alcohol or medication.
5. ALWAYS ensure the workpiece is firmly secured leaving both hands free to
control the wrench. Hold the impact wrench correctly and be ready to
control sudden movements.
6. ALWAYS check for any damage or condition that could affect the
wrench’s operation. Any damaged part should be properly repaired.
7. NEVER force or misuse the wrench. It will do a better and safer job at the
rate for which it was designed.
8. NEVER use the wrench if it is defective / operating abnormally.

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9. NEVER carry the wrench with your finger on the trigger.
10. NEVER abuse the mains cable of the battery charger. Never pull the cable
to disconnect it from the socket. Keep the cable away from sharp edges/
hot surfaces.
11. NEVER use this wrench for any purpose other than described in this booklet.
12. NEVER carry out any alterations or modifications to this product.
13. NEVER wipe the wrench clean with solvents. Wipe plastic parts with a soft
cloth, slightly dampened with soapy water.
14. NEVER attempt any repairs yourself. If you have a problem with this product
contact your local CLARKE dealer.
15. ALWAYS use an approved cable extension suitable for the power rating of
the battery charger (see specifications), the conductor size should also be
at least the same size or larger than that on the charger. When using a
cable reel, always unwind the cable completely.
IMPACT WRENCH SAFETY INSTRUCTIONS
1. USE ONLY IMPACT WRENCH SOCKETS....DO NOT use standard sockets which
could shatter and cause injury.
2. ALWAYS finish tightening nuts with a torque wrench to the correct torque as
recommended by the vehicle manufacturer.
3. ALWAYS avoid excessive use of the wrench. When tightening a nut or bolt,
always avoid over tightening.
4. ALWAYS ensure the wrench has stopped before putting it down after use.
5. ALWAYS set the forward/reverse selection bar to neutral/lock when
changing sockets or when the wrench is not required for immediate use.
This will avoid accidental starting.
6. NEVER point the LED light at persons or animals.
LITHIUM-ION BATTERY USE AND CARE
1. Only use the wrench with the battery pack supplied. Use of any another
battery pack may create a risk of injury and fire.
2. DO NOT charge the battery when the room temperature is below 5oC. DO
NOT store the battery where the temperature may exceed 40oC (104oF)
3. When the battery pack is not in use, keep it away from metal objects that
could make a connection from one terminal to another. Shorting the
battery terminals together may cause burns or a fire.
4. Dispose of spent batteries correctly as they contain Lithium-ion. They are re-
cyclable and should be taken to a recycling centre to be disposed of as

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stipulated by local regulations. DO NOT incinerated battery as it may
explode when exposed to fire. DO NOT attempt to open, disassemble,
modify or service a battery pack.
5. Handle batteries so as to avoid damage, fire, corrosion or personal injury.
6. Never crush, puncture, short external contacts or dispose of in water.
7. Never attempt recharging the battery by means of an engine generator or
a DC power source.
ENVIRONMENTAL PROTECTION
Do not dispose of this product with general household waste. All tools,
accessories and packaging should be sorted, taken to a recycling centre and
disposed of according to the laws governing Waste Electrical and Electronic
Equipment.
Through the purchase of this product, the customer is taking on the obligation
to deal with the WEEE in accordance with the WEEE regulations in relation to
the treatment, recycling & recovery and environmentally sound disposal of
the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
BATTERY DISPOSAL
Dispose of old batteries in accordance with local authority regulations. DO
NOT incinerate or crush, as this will increase the risk of explosion and
contamination. If the battery contents come into contact with skin or the eyes,
rinse with clean water for several minutes and seek medical advice
immediately afterwards.

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ELECTRICAL CONNECTIONS
The battery charger for this product is provided with a standard 5 amp, 230
volt (50Hz), BS 1363 plug, for connection to a standard, domestic electrical
supply. Should the plug need changing at any time, ensure that a plug of
identical specification is used.
If the colours of the wires in the power cable of this product do not correspond
with the markings on the terminals of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal
which is marked Nor coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked Lor coloured Red.
We strongly recommend that this machine is connected to the mains supply
via a Residual Current Device (RCD).
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.
This symbol indicates that this is a Class II product and does not require
an earth connection.
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
WARNING! THE WIRES IN THE POWER CABLE OF THIS PRODUCT
ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE
Plug must be BS1363/A approved.
Always fit a 3 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)

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PRODUCT OVERVIEW
The CCIW160 is a cordless impact wrench which is rechargeable using the
mains charging unit. The key design features are shown above.
Upon receipt, check the components against the following list. Any damage
or deficiency should be reported to your CLARKE dealer immediately.
Component Quantity
18V Impact Wrench 1
18V 2AH Battery Pack 2
230V Battery Pack Charging Unit 1

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BATTERY CHARGING
The battery will have been shipped in a low charge state and will require
charging before first time use.
1. Press the battery release clip on
the front of the battery pack.
2. Slide the battery pack from the
impact wrench.
3. Plug the charger into a 230V
power supply and switch ON.
• The green POWER ON light will
illuminate to show the unit is
connected to the mains supply.
4. Insert the battery pack into the
battery charger, as shown, noting
that it will only fit one way.
• The red light will come on to
indicate the battery is charging.
• When charging is complete, the
red light will go off and the
green light will come on. The
battery pack can be
considered charged and be
removed. Charging time will be
dependant upon the initial state
of the battery.
• When charging a new battery pack, it may initially not accept full
charge. This is common & does not indicate a fault. It can be
recharged fully after it has been discharged a couple of times.
• If charging does not take place, ensure all connections are clean.
• In the event of both LED indicators flashing rapidly, it can be
assumed that either the battery has become too hot, in which case
it should be left to cool down, or that a battery cell has failed and
the battery should be replaced.
5. After charging, switch off and unplug the charger from the power supply.
6. Remove the battery pack from the charger and slide it back onto the
impact wrench until it clips into place.

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NOTE: On the rear of the
battery are 3 red power
indicator lights. Press the
power indicator button
to show how much
power the battery has.
• 1 Light: Low power
•2Lights:Mediumpower
• 3 Lights: High power
The battery pack should slide in easily. If it is not to be fitted immediately,
ensure that the metal contacts are protected to avoid the possibility of a short
circuit which would cause battery damage. For maximum battery life, we
recommend that you maintain the battery in a fully charged state.
OPERATION
FITTING A SOCKET
1. Align the chosen socket and
simply push it onto the anvil. Use
only ½” square drive impact
sockets as listed on page 11.
2. Select Forward or Reverse on the
selector bar.
3. Squeeze the trigger to start the
impact wrench. Release the
trigger to stop.
CAUTION: MAKE SURE THAT THE IMPACT WRENCH IS OFF USING THE
SELECTOR BAR BEFORE ATTACHING OR REMOVING A SOCKET. ALWAYS
TAKE CARE TO USE THE CORRECT SIZE SOCKET FOR BOLTS AND NUTS. AN
INCORRECT SOCKET WILL CAUSE DAMAGE TO THE BOLT OR NUT.

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FORWARD/REVERSE/LOCK SELECTION
1. Select the direction of operation
by pushing the selector bar in the
appropriate direction.
• The direction of rotation is
shown on the end face of the
selector bar.
• When the selector bar is in the
central position the trigger is in
neutral/locked.
2. Always check the direction of
rotation before operation.
LOOSENING A NUT
1. Fit the appropriate socket to the square drive of the impact wrench.
2. With the FORWARD/REVERSE selector bar in the REVERSE running position,
hold the wrench firmly and pull the trigger. The nut will be impacted
repeatedly until it is loosened.
NOTE: As the battery becomes discharged the power available will
drop. The battery will cut out when a low state of charge is
reached. This is normal and is a design feature to protect the
battery from deep discharge. If this occurs, re-charge the battery
as described on page 8.
3. After use, recharge the battery pack as shown on page 8. Avoid leaving
the batteries in a discharged state.
TIGHTENING A NUT
1. Start the nut by hand, ensuring it is not cross threaded, then with the
appropriate socket fitted to the impact wrench, place it on the nut.
2. With the FORWARD/REVERSE selector bar in the forward running position,
and holding the wrench firmly, pull the trigger.
3. Install each nut in turn until it is ‘nipped’ up only - do not tighten fully. When
all nuts are secure, tighten further but take care to prevent over-tightening.
4. ALWAYS finish tightening with a torque wrench to the manufacturers
recommended torque.
WARNING: ENSURE THAT THE CORRECT SOCKET IS BEING USED FOR THE
NUTS ON YOUR PARTICULAR VEHICLE. AN INCORRECT SOCKET SIZE WILL
DAMAGE THE HEADS OF THE BOLTS/NUTS.

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BELT HOOK
The impact wrench is provided with a
belt hook. This can be fitted to either
side of the main housing, adjacent to
the battery and is retained by a
single screw.
MAINTENANCE
All bearings etc, in this wrench are lubricated with a sufficient amount of high
grade lubricant for the machines lifetime under normal operating conditions,
therefore no further lubrication is required.
Refer to your CLARKE dealer if internal maintenance is required.
Check the battery charger power cable to ensure it is free from cracks, bare
wires etc.
Avoid using solvents when cleaning plastic parts, most plastics are susceptible
to damage from the various types of commercial solvents. Keep the unit clean
by wiping with a dry cloth. DO NOT use solvents as a cleaning agent.
Your CLARKE impact wrench has been designed to give long and trouble free
service. If, however, having followed the instructions in this booklet carefully,
you encounter problems, take the unit to your local CLARKE dealer.
Always store the wrench and its charger in the case supplied. Store in a clean,
dry place, out of reach of children when not in use.
ACCESSORIES
A wide range of impact wrench accessories are available from your nearest
CLARKE dealer, for further information, contact your nearest dealer, or
telephone CLARKE International Sales department on 01992 565300.
Suitable impact wrench socket sets include the following:
Part No Model No Description
3110875 CIS12/10 1/2” Drive Impact Socket Set
3110437 CIS12/11 11 Piece Impact Socket Set

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COMPONENT PARTS LIST
1700726 CIS12/6SB 6 Piece Impact Spline Bit Set - 1/2” Drive
1700732 CIS12/3M 3 Piece 1/2” Drive Non Slip Impact Socket Set
1800311 CIS12/17B 16 Piece Deep Impact Socket Set
1800350 CIS12/7DM 7 Piece 1/2”Universal Joint Deep Socket Set
1800141 CHT141 1/2” Drive Torque Wrench
No Description No Description
1 ST3 x 13 - F Screw 19 Planetary Wheel
2 Right Foot Plate Housing 20 Striking Block Assembly
3 Right Side Main Body Case 21 Output Shaft
4 Nameplate 22 Plastic Gasket
5 Hex Nut M4 x 3.2 23 Bushing
6 Platform Battery Clip 24 Head Shell
7 Reversing Lever 25 Spring Washers
8 Switch (CD-L0118) 26 Cross Pan Head Tapping Screws
9 18V Battery Pack 27 Rubber Cover
10 18V Battery Charger 28 Left Hand Side Main Body Case
11 Drive Motor 29 Left Foot Plate Housing
12 Motor Gear 30 Oil Proof Gasket
13 Tooth Box (CW-L0318) 31 Belt Hook
14 Crosshead Round Base Screws 32 Cross Countersunk Head Screws
15 Inner Ring Gear 33 Lanyard
16 Bearing 6802-2RS 34 Cylindrical Pin
17 Bearing Gasket 35 Rubber Stopper
18 Cylindrical Pins

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COMPONENT PARTS DIAGRAM

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CCIW160 SPECIFICATIONS
Please note that the details and specifications contained herein, are correct at
the time of going to print. However, CLARKE International reserve the right to
change specifications at any time without prior notice.
WRENCH FEATURE SPECIFICATION
Weight (Impact Wrench) 1.15 kg
Dimensions (L x W x H) 180 x 84 (70 without belt hook) x 200 mm
Size of spindle 12.7mm / 1/2”
Max. Bolt Diameter Standard Bolt: M8 - M16 (5/16” - 5/8”)
High Tensile Bolt: M6 - M12 (1/4” - 1/2”)
Max rated tightening torque 160 Nm
Rated no-load speeds 0-2200 rpm
Impacts/minute 0-2800 max.
Duty Cycle S1 (continuous)
IP Rating IPX0
Sound pressure level 83 dB LpA
Guaranteed sound power
level
94 dB LWA
Uncertainty Factor (K) 3 m/s2
Vibration Level 4.825 m/s2
Uncertainty Factor (K) 1.5 m/s2
BATTERY/CHARGER FEATURE SPECIFICATION
Charger insulation class II
Input voltage (Charger) 230V/50 Hz
Output voltage (Battery) 18V DC
Battery Type Lithium-Ion
Charging Time 60 mins
Battery pack capacity 2000 mAh
Charger fuse rating 3 Amp

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DECLARATION OF CONFORMITY