Clarke CIR450 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0309
PROFESSIONAL CORDLESS
IMPACT WRENCH
Model CIR450
Part No 4500630

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INTRODUCTION
Thank you for purchasing this CLARKE Impact Wrench.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also look forward to the product giving you long and satisfactory service.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt 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.
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.
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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CONTENTS
Introduction ............................................................................................ 2
Guarantee .............................................................................................. 2
Environmental Protection ...................................................................... 2
Component Inventory ........................................................................... 3
Safety Precautions ................................................................................. 4
Electrical Connections .......................................................................... 6
Safety Symbols ....................................................................................... 7
Component Identification .................................................................... 7
Initial Battery Charging ......................................................................... 9
Operation ............................................................................................... 9
Recharging ........................................................................................... 11
Maintenance ........................................................................................ 11
Parts List and Diagram......................................................................... 12
Parts & Service Contacts ..................................................................... 12
Technical Specifications ..................................................................... 14
Accessories .......................................................................................... 14
Declaration of Conformity .................................................................. 15
COMPONENT INVENTORY
The CIR450 is a professional, cordless impact wrench which is rechargeable
using the mains power adaptor.
Upon receipt, unpack and lay out the components, checking against the
following list. Any damage or deficiency should be reported to your CLARKE
dealer immediately.
1. 24V Impact Wrench with 1.7Ah battery cartridge
2. Battery-charging unit
3. Side handle
4. Moulded tool-case
5. Operators manual (this document)

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SAFETY PRECAUTIONS
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 wrench.
4. 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.
5. Although the impact wrench may be used outdoors, DO NOT leave it
exposed to the elements. Avoid direct sunlight, direct heat, rain/moisture
etc.
6. Always keep body and clothing dry. Never work in damp area without
adequate insulation against electric shock.
7. Do not fit the wrench to a stand or clamping device that may damage it.
GENERAL USE
1. This product vibrates during use. Vibration may be harmful to your hands
or arms. Stop using the machine if discomfort, a tingling feeling or pain
occurs and seek medical advice before resuming use.
2. ALWAYS use ear defenders.
3. ALWAYS stay alert and use common sense - do not use this product when
you are tired or under the influence of alcohol or medication.
4. ALWAYS ensure that the socket is correctly installed before switching on.
5. ALWAYS only use sockets which are specified for impact wrench use.
6. ALWAYS ensure the workpiece is firmly secured leaving both hands free to
control the impact wrench.
7. ALWAYS store this product in a dry, secure place out of reach of children
or untrained users.
8. ALWAYS keep all equipment dry especially the battery & battery charger.
9. ALWAYS keep metal objects such as coins, keys, nails or other small metal
objects which could make a connection from one terminal to another,
away from the battery cartridge. A short circuit across the terminals could
cause sparks, burns or start a fire.
10. ALWAYS ensure the machine has stopped before putting it down after use.
11. ALWAYS set the forward/reverse Switch-bar to neutral when changing bits
or when the machine is not required for immediate use. This will avoid
accidental starting.

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12. ALWAYS check for any damage or any condition that could affect its
operation. Any damaged part should be properly repaired.
13. NEVER force or misuse the machine. It will do a better and safer job at the
rate for which it was designed.
14. NEVER use this product if it is defective / operating abnormally.
15. NEVER carry the machine with your finger on the trigger.
16. NEVER abuse the mains cable of the battery charger. Never yank the
cable to disconnect it from the socket. Keep the cable away from sharp
edges/hot surfaces.
17.NEVER over-reach. Keep proper footing and balance at all times.
18. NEVER use this product for any other purpose than that described in this
booklet.
19. NEVER carry out any alterations or modifications to this product.
20. NEVER attempt to wipe the machine clean with solvents. Wipe plastic
parts with a soft cloth, slightly dampened with soapy water.
21. NEVER attempt any repairs yourself. If you have a problem with this
product contact your local CLARKE dealer.
IMPACT WRENCH SAFETY INSTRUCTIONS
1. ALWAYS use the impact wrench in the manner and for the functions
described in these instructions.
2. ALWAYS ensure the machine is not moving with the switchbar in the centre
position 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,
never allow the wrench to impact more than 8 times - to avoid over
tightening - 3 to 4 impacts is normally sufficient.
5. ALWAYS use outdoor extension leads if working outdoors. 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.
Additionally, please keep these instructions in a safe place for future reference.

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ELECTRICAL CONNECTIONS
This product is provided with a 13 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.
The battery charger for this appliance is of double insulated design
No earth conductor is provided. The two wires in the mains lead should be
wired up in accordance with the following colour code:
Blue — Neutral
Brown — Live
Connect the BROWN coloured cord to the plug terminal marked a letter “L”
Connect the BLUE coloured cord to the plug terminal marked a letter “N”
If the battery charger for this appliance is fitted with a plug which is moulded
on to the electric cable (i.e. non-rewireable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace the fuse cover, ensure that the correct
replacement is used (as indicated by marking or colour code).
4. Replacement fuse covers can be obtained from your local Clarke dealer
or most electrical stockists.
FUSE RATING
The fuse in the plug must be replaced with one of the same rating and this
replacement must be ASTA approved to BS1362.
If in any doubt, consult a qualified electrician. DO NOT attempt any electrical
repairs yourself.
CABLE EXTENSION
Do not use an extension longer than 10 metres and one where the
conductors, are less than 1.5mm2.
If used outdoors, ensure the extension cable is designed for outdoor use.

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COMPONENT IDENTIFICATION
1. 1/2” Square Socket Drive
2. Battery Release Button
3. Forward/Reverse Switch-bar
4. Battery Pack
5. Trigger
6. Wrist Strap
7. Hand Grip
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.
Class II appliance which does not need an earth connection
For indoor use only
Read the manual before operating this machine
Falls under the Waste Electrical & Electronic Equipment directive
(WEEE)
European Certificate of Conformity
FIG 1

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BATTERY CHARGING
1. The new battery pack will require
charging before use.
2. Squeeze the battery release buttons on
either side of the battery pack and pull
gently down to disengage the battery
pack from the machine as in Fig 1.
3. Insert the battery pack into the battery
charger, as shown in Fig 2, noting that it
will only fit one way.
4. Plug the charger into a 230v (mains)
power supply and switch ON.
• The green POWER ON light will
illuminate with the RED charging light
flashing and charging will begin.
• If charging does not take place,
ensure all connections are clean
and free of grease etc.
• If the red charging light will not stay
on for more than a few moments, the battery
pack is likely to be defective and it must be
replaced with a new one.
• When the RED charging light goes out
after about 1/2 hour, and the GREEN
light remains on, the battery pack can
be considered charged and be
removed. The charging time will be
dependant upon the initial state of the
batteries.
• 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.
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 into the
machine until it clips into place. The
battery pack should slide in easily.
FIG 1
FIG 2

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If the battery pack is not to be fitted immediately, ensure that the metal contacts
are protected so as to avoid the possibility of a short circuit which would cause
damage.
Remember to avoid extremes of heat or cold when charging. Avoid temperatures
outside the range of Minimum 4°C /Maximum 50°C. Avoid placing batteries in
direct strong sunlight or other heat source.
NOTE: Ni-Cad batteries as used in Clarke cordless power tools should be given a
full charge when first supplied new. Maximum battery performance will be
achieved after approximately 5 complete charge/discharge cycles.
The battery should be fully discharged before recharging in order to achieve its
optimum performance. Constant topping up after only a small amount of charge
has been used will, in effect, reduce its capacity.
Nickel cadmium batteries will slowly lose their power whilst in storage. If they
become fully discharged, no not leave the batteries in this state for any length of
time.
OPERATION
CAUTION: ALWAYS BE SURE THAT THE TOOL IS SWITCHED OFF 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.
1. Align the chosen socket and simply push it onto the anvil. Use only
½”square drive impact sockets as listed on
page 14.
2. Squeeze the trigger to start the machine.
Release the trigger to stop.
3. To run the impact wrench in reverse, push the
switch-bar through the drive unit as shown in Fig
3. The direction of rotation is shown on the end
face of the switch-bar.
• The 3-position switch bar controls forward or
reverse direction of rotation. Select the
appropriate position ONLY when the machine is
STATIONARY. Do not move the switch-bar when
the spindle is moving. When the switch-bar is in
the central position the trigger is locked.
4. Always check the direction of rotation before
operation.
5. Turn off the machine as soon as the impact
sound is heard. FIG 3

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Note: As the battery becomes discharged, the power available will drop.
Operating the machine at low speed will cause a reduction in torque.
6. After use, recharge the battery pack as shown on pages 8-9. Avoid
leaving your batteries in a discharged state.
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 switchbar 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 immediately 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.
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.
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 switch-bar 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 for 3 to 4 impacts only 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.