Clarke Air CAT62 Installations- und Betriebshandbuch

OPERATING & MAINTENANCE

INSTRUCTIONS

GC0115

PUNCH & FLANGE TOOL

MODEL NO: CAT62

PART NO: 3110462

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

INTRODUCTION

Thank you for purchasing this CLARKE Air Tool.

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.

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.

USE

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

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

2. Always wear eye protectors when using air tools. Eye protectors must

provide protection from flying particles from the front and the side.

3. Do not overreach - Keep proper footing and balance at all times.

4. Never use oxygen, CO2, combustible gasses, or any bottled gas, as a

source of power for the grease gun. This product should only be used with

a suitably rated compressed air supply.

5. Do not connect the air supply hose with your finger on the trigger of the

gun.

6. Do not fit the tool to any stand or clamping device that may damage it.

7. Do not exceed the maximum pressure for the tool of 90 psi / 6.2 bar.

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

9. Check hoses for leaks or excessive wear before use, and ensure that all

connections are secure.

10. Do not use the tool for any other purpose than 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.

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

13. This tool should be serviced at regular intervals by qualified service

personnel.

14. Avoid damaging the tool for example by applying excessive force.

15. Always maintain the tool with care. Keep it clean for the best and safest

performance.

16. Do not force or misuse the tool. It will do a better and safer job at the rate

for which it was designed.

HAZARDS SPECIFIC TO CUTTING/PUNCHING TOOLS

1. Be careful around all moving parts and pinch points. Always keep your

fingers away from the point of cutting.

2. Ensure material is properly supported during cutting. Use supports for long

material. Hold the material securely to prevent it tilting during the cut. Use

clamps or vices to hold the work piece whenever possible.

3. Take care of sharp edges produced by the work.

4. Do not use damaged punches. When replacing cutting tool parts, make

sure they are correctly and securely fitted.

5. Anticipate the unexpected tool movement due to a binding punch.

Release the trigger immediately if this occurs.

TRANSPORTATION

1. Never carry an air tool by the air supply hose.

2. Never carry an air tool with your finger on the trigger.

STORAGE

1. 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 (preferably in a locked

cabinet).

2. Avoid storing in cold environments.

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

OVERVIEW

The CAT62 Punch and Flange tool is suitable for heavy bodyshop use.

It has an aluminium alloy body with steel punch and die and puts a 10mm

flange onto car panel thickness sheet for lap jointing and puts 5mm holes in

panels for MIG spot-welding.

NO DESCRIPTION NO DESCRIPTION

1 Punch opening 5 Air Cylinder

2Clamp 6ValveBody

3 Anvil 7 Air Inlet

4 Hydraulic Cylinder 8 Trigger

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 & topped up with oil. Clarke air-line oil should

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

• 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 A 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 inlet 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 helpful for

sealing threaded connections.

6. 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).

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

OPERATION

1. Connect the tool to the air supply.

2. To start the tool, hold firmly and squeeze the throttle lever.

• The clamp will move down, punching a hole or forming a flange, as

required.

3. Release the lever and the clamp will rise allowing the tool to be positioned

for the next operation.

4. After use, disconnect the tool from the air supply, clean and store in a safe,

dry, childproof location.

NOTE: It is recommended that a whip hose with a swivel (not included)

be used to prevent twisting, kinking and resultant wear to the air

hose.

DISCONNECTING THE AIR SUPPLY

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

down and the compressed air released.

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

and release the compressed air.

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

the air tool.

3. Store the tool safely in its box in a dry, secure environment.

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

MAINTENANCE

DAILY

1. Before use, drain water from the air-line and compressor.

2. This air tool should be lubricated before use. Turn the tool upside down and

pour 1-2 drops of Clarke air-line oil into the 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 hours

of constant use.

3. Keep the tool clean.

SERVICING

For a full service contact your local Clarke Service Department.

To remove and replace the punch (6) and/or die (3) proceed as follows:.

Numbers refer to the parts list and diagram on pages 12/13.

1. Remove screws (7) and slide off cover plate (8).

2. Slacken set screw (2) and strike rear edge of clamp (1) with a soft-headed

hammer in order to unscrew it from the shaft of the hydraulic piston (31). If

necessary the shaft may be locked by removing the oil plug (13) and

inserting a suitable rod into a hole in the shaft.

3. Fully unscrew the clamp (1) and anvil (9) assembly from the shaft.

4. Separate the anvil (9) and the clamp (1) to replace the punch (6) and/or

die. The die (3) is a push fit in the clamp (1) and can be tapped out via the

waste bore (A). Push/tap in the replacement.

5. Reassemble the anvil (9), clamp (1) and the replacement punch (6) and

screw onto the shaft. Tap with a soft-headed hammer to ensure tightness

and lock with the set screw (2).

6. Refit the cover plate (8) and retain with screws (7).

Deposits in the tool may also reduce efficiency. This can be corrected by

cleaning the air inlet and flushing out the tool with gum solvent oil, or failing

this, the tool should be disassembled, thoroughly cleaned, dried and

reassembled.

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

If the tool becomes inefficient and the air supply is of good quality, it may be

necessary to replace worn or damaged parts. You may prefer to take the tool

to your Clarke dealer if internal maintenance is required.

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-lne 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.

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, disconnect from air supply, clean and store in a safe, dry

place.

ACCESSORIES

A wide range of airline accessories is available including filter/regulators,

lubricators, high-pressure hoses (5 to 50 metres) etc.

Contact your Clarke dealer or Clarke International Service Department for

further information.

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