Clarke CAT216 Installations- und Betriebshandbuch

OPERATING & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC04/22

3/16”PUNCH & FLANGE TOOL

MODEL NO: CAT216

PART NO: 3110470

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

INTRODUCTION

Thank you for purchasing this CLARKE Punch and Flange forming 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.

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

SPECIFICATION

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 affect your

statutory rights

Model Number CAT216

Part Number 3110470

Dimensions (L x W x H) 250 x 60 x 60 mm

Max Operating Pressure 90 psi (6.2 bar)

Average Air Consumption 4 cfm (1.88l/s)

Air Inlet Size 1/4“BSP female

Min Hose Diameter 3/8 in

Punch Diameter 3/16 in

Maximum Punching Capacity 16-gauge (1.5mm) sheet metal

Maximum Crimping Capacity 14-gauge (1.8mm) sheet metal

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

GENERAL SAFETY RULES

THE 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 AIR POWERED 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 gases 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. Check hoses for leaks or worn condition before use and ensure that all

connections are secure.

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

9. DO NOT use the tool for any purpose than that described in this manual.

10. DO NOT fit the tool to any stand or clamping device that may damage it.

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 service

personnel.

15. Avoid damaging the tool for example by applying excessive force of any

kind.

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.

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.

TRANSPORT & STORAGE

1. DO NOT carry the tool by the air hose.

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

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

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

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

COMPRESSED AIR REQUIREMENTS

A typical air line layout is shown below. If an automatic in-line filter/regulator is

used, it will keep air tools in good condition but should be regularly checked

and topped up with oil. CLARKE airline oil should be used and the lubricator

be adjusted to approx 2 drops per minute.

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

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.

The air hose must be rated at least 150% of the maximum operating pressure of

the tool.

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

used.

Set the tool in the OFF position before connecting it to the air supply.

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 by up to 15 psi to maintain air

pressure at the tool.

Never exceed the maximum operating pressure for the air tool. It is

recommended that air pressure to this tool does not exceed 90 psi at the air

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.

Check hoses for wear or damage before use.

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

PRODUCT OVERVIEW

The CAT216 Punch and Flange forming tool is a versatile 2 in 1 tool designed to

crimp and punch mild steel. It has an aluminium alloy body with steel punch

and die and puts a flange onto car panel thickness sheet for lap jointing and

puts 3/16in holes in panels for MIG spot-welding or riveting.

NO DESCRIPTION NO DESCRIPTION

1 Clamp 6 Trigger

2 Anvil 7 Oil plug

3 Punch Die 8 Air Cylinder

4 Punch 9 Air Inlet

5 Hydraulic Cylinder 10 Airline adaptor

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

BEFORE USE

CONNECTING THE AIRLINE

NOTE: Ensure the air supply is turned off.

1. Remove the travel plug.

2. If required, connect an in-line mini

oiler to the tool. Refer to the

instructions supplied with the mini-

oiler before use.

• A mini oiler helps to prolong the

life of any air tool.

3. Connect a suitable hose. This can

be done using either the male

adaptor supplied or using a mini

oiler from your CLARKE dealer.

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 the other end of the hose to the compressor.

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

proceeding. Set the working pressure to 90psi/6.2 bar for best

performance.

• PTFE tape may be useful for sealing threaded connections.

7. 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 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).

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU

ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR

COMPRESSORS AND A COMPRESSED AIR SUPPLY.

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

OPERATION

1. Connect the tool to the air supply.

FLANGING

IMPORTANT: If you intend to flange and punch the workpiece, flange it first

and then measure for hole placement. Flanging will change the dimensions

of the workpiece.

1. Measure and cut the workpiece to the correct dimensions.

2. Secure the workpiece in a vice or another appropriate clamping method if

needed.

3. Insert the workpiece into the flanging jaw between the anvil (2) and the

clamp (1). Make sure that the workpiece is flush against the back of both

the anvil and the clamp. Depress the trigger (6) and the anvil will be driven

against the clamp forming a flange.

4. Release the trigger. Slide the punch/flange tool along the edge of the

workpiece to where the anvil (2) and the clamp (1) overlap part of the

workpiece you just flanged. Repeat Step 3.

5. Repeat steps 3 and 4 until the entire flange is finished.

6. Disconnect the tool from the air supply.

PUNCHING

NOTE: The tool head can be rotated 360 degrees. Just manually rotate

the tool head clockwise or counterclockwise within a half

round to make the necessary adjustment.

1. Mark the desired location on the workpiece of each hole you wish to

punch.

2. Insert the edge of the workpiece between the punch die (3)

and punch (4). Make sure that your marks are aligned with the punch die.

3. Depress the trigger (6) and the punch will pierce the workpiece.

4. Align the punch/flange tool with the next mark on the workpiece

and repeat Step 3 until the job is finished.

5. Disconnect the tool from the air supply.

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.

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

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 air tool.

3. Shut down the compressor at the end of the work session and drain daily as

recommended.

STORAGE

When not in use, disconnect from the air supply, clean & store in a safe, dry

place.

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. When storing, replace the blanking plug on the

airline inlet.

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

MAINTENANCE

DAILY

1. Before use, drain water from the compressed air supply.

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.

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

COMPRESSED AIR SUPPLY BEFORE STARTING ANY CLEANING OR

MAINTENANCE PROCEDURES.

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