Clarke CAT51 Installations- und Betriebshandbuch

OPERATING & MAINTENANCE

INSTRUCTIONS

GC0315

NEEDLE SCALER

MODEL NO: CAT51

PART NO: 3110565

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

INTRODUCTION

Thank you for purchasing this CLARKE Needle Scaler.

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.

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.

SPECIFICATION

Model Number CAT51

Min. Hose Size (ID) 8mm (5/16” BSP

Max Operating Pressure 90 psi (6.2 bar)

Max Air Consumption 5 cfm (average)

Blows per minute 4500 (@ 6.2 bar)

Piston Stroke 27 mm

Air Inlet Size 1/4“BSP Female

Sound Pressure Level (LpA dB) 95.1 dB(A)

Sound Power Level (LwA dB) 106.1 dB(A)

Vibration Levels 18.2 m/s2

Weight 2.8 kg

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

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 POWER TOOLS

1. Stay alert and use common sense - do not operate the tool when you are

tired or under the influence of alcohol, drugs or medication.

2. Always wear eye protectors when using the tool. 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 gasses or 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 tool of 90 psi / 6.2 bar.

7. Keep the air supply hose away from heat, oil and sharp edges.

8. Do not fit the tool to any 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.

• The tool will be left unattended.

CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN

PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

• Moving to another work area.

• Passing the tool to another person.

13. Never use the tool if it is defective or operating abnormally.

14. This tool should be serviced at regular intervals by qualified personnel.

15. Avoid damaging the tool f 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.

TRANSPORT & STORAGE

1. Never carry the tool by the air hose or with your finger on the trigger.

2. Always disconnect from the air supply when changing bits or when the tool

is not required for immediate use in order to avoid accidental starting.

3. Always use both hands to control the tool.

4. Always ensure the tool has stopped before putting it down after use

5. When not in use the tool must be disconnected from the air supply and

stored in a dry place out of the reach of children.

6. Avoid storing the tool where the temperature is below 0oC.

Please keep these instructions in a safe place for future reference.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

COMPRESSED AIR 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. clarke airline oil should

be used, and the lubricator adjusted to approx 2 drops per minute.

• For optimum performance it is recommended that a 3/8” ID hose is

used.

• 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 dirty 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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

BEFORE USE

NOTE: Ensure the compressor is turned off.

1. If required, connect an in-line mini oiler to the tool.

• A mini oiler helps to prolong the life of the air tool.

2. 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.

3. Connect a suitable hose as shown.

4. Connect the other end of the hose to the compressor.

5. Turn on the air supply and check for air leaks. Rectify any found before

proceeding.

• PTFE tape may be useful for sealing threaded connections.

Your air tool is now ready for use.

OPERATION

FITTING THE NEEDLE HOLDER

The Scaler is packed in two halves.

1. The main body and hammer assembly

2. The needles with needle holder, needle tube and spring

The needles, needle holder and spring, are inserted in the Needle Tube in the

manner shown in fig. 1, ensuring the Needle Holder is the correct way round,

so that the heads of the Needles sit snugly in the recesses provided in the

Holder.

Push the needle tube, complete with needles, needle holder and spring, on to

the main body so that the retaining lug, in the body, enters the slot in the side

of the tube, shown in fig. 1. Continue to push against spring pressure until the

body may be twisted, and thereby locked, into one of three positions.

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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

The first position, achieved by turning the body and the retaining lug

anticlockwise, creates the greatest needle force, the second position,

achieved by pushing harder against spring pressure and turning the body

clockwise, creates a slightly lesser force, and the third position, achieved in a similar

manner, creates even less. A position should be selected depending upon your

requirements, dictated by the finish required and the type of material being worked.

A gauze filter is fitted within the air inlet adapter. Ensure this filter is always in

place and clean. An air line is connected to the adapter, preferably via a

quick release coupling (not supplied).

Ensure the operating lever is NOT depressed when connecting the air line.

USING THE TOOL

Hold the tool with the fingers of one hand wrapped around the operating

lever, and bring towards the work at an angle of approx.60-70o. With the

airline pressure set to 90 lbf/in2(6.1bar), pull the operating lever and allow the

needles to come into contact with the work.

Moving slowly across the work surface, proceed to remove scale, rust or other

contaminants.

Release the trigger to stop operation, noting that the tool may impact briefly

after the trigger is released.

DISCONNECTING THE AIR SUPPLY

1. Do not disconnect the air supply hose until the compressor has been shut

down and the compressed air released.

2. Refer to the compressor instruction manual for the procedure to shut down

and vent the compressed air.

3. Once the pressure has been released, disconnect the air supply hose from

the air tool.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

MAINTENANCE

DAILY

1. Before use, drain water from the airline filter and compressor.

2. Pour a few drops of Clarke air-line oil, into the tool air inlet. This should be

carried out regardless of whether or not an in-line mini oiler is used. If an in-

line mini oiler is not used, this procedure should be repeated after every

two to three hours of use, or at the start of the working day.

3. Keep the body of the tool clean and free from debris.

CLEANING

1. Keep the body of the tool clean and free from debris.

2. Grit or gum deposits in the tool may also reduce efficiency. This condition

can be corrected by cleaning the air strainer and flushing out the tool with

gum solvent oil, or failing this, the tool should be disassembled, thoroughly

cleaned, dried and reassembled.

3. After extensive use, remove the inlet screen filter and flush out the

mechanism with gum solvent oil or an equal mixture of SAE No10 oil and

paraffin. Allow to dry before use.

4. If the tool 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.

STORAGE AND SPARE PARTS

1. 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 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.

2. 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 the Clarke International Service

Department.

• Replacement needle set;- Clarke part no; 3110566.

WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE

AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE

PROCEDURES.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

TROUBLESHOOTING

PERFORMANCE

Please note that factors other than the tool 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.

**Clarke Air Line Oil (part no. 3050825) is available from your Clarke dealer.

Your Clarke air tool 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.

SYMPTOM PROBLEM SOLUTION

Tool runs at normal

speed but slows down

under any load.

1. Piston 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. Moving 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. 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. Piston 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.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

COMPONENT PARTS

No Description No Description

1 Main Body 15 Front Valve Block

2 O-Ring 16 Piston

3 Throttle Valve 17 Barrel Sleeve

4 Spring 18 Nose

5Gasket 19Key

6 Valve Cap 20 Driver Retainer

7 Lever 21 Retainer Buffer

8 Pin 22 Barrel Assembly

9 Hose Adaptor 23 Retainer Clip

10 Locking Ring 24 Needle Driver

11 Alignment Shim 25 Needle (19)

12 Rear Valve Block 26 Needle Holder

13 Pin (2) 27 Spring

14 Valve 28 Needle Tube

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