Clarke CAT189 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0619 - ISS 1
AIRLINE REGULATOR
MODEL NO: CAT189
PART NO: 31205506

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INTRODUCTION
Thank you for purchasing this CLARKE Airline Regulator.
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.
Your regulator 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.
SPECIFICATIONS
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.
CAT189
Dimensions (D x W x H) mm 100 x 68 x 250
Air Inlet /Outlet Size 3/4“BSP
(female)
Max Flow 220 CFM
Max Inlet Pressure 300 psi
Regulating range 5-150 psi
Max working Temperature 175 deg F
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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3. Keep children and visitors away - do not let children handle the tools.
4. Do not operate air tools where there are flammable liquids or gases.
USE OF AIRLINE EQUIPMENT
1. Stay alert and use common sense - do not operate an air tool when you
are tired or under the influence of alcohol, drugs or medication.
2. Do not overreach - Keep proper footing and balance at all times.
3. Never use oxygen, CO2, combustible gases or any type of bottled gas as a
source of power for air tools.
4. Do not exceed the maximum pressure for the airline component stated in
the specification.
5. Check airline hoses for leaks or worn condition before use and ensure that
all connections are secure.
6. Keep the air supply hose away from heat, oil and sharp edges.
7. Avoid damaging the component for example by applying excessive force
of any kind.
8. Always maintain the air tool with care. Keep it clean for the best and safest
performance.
COMPRESSED AIRLINE REQUIREMENTS
1. Use only clean, dry, regulated compressed air as a power source.
2. Air compressors must comply with the appropriate European Community
Safety Directives.
3. A build-up of moisture in the air compressor will accelerate wear and
corrosion in the air tool. Ensure any moisture is drained from the compressor
daily and the airline filter is kept clean.
4. 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 air tool.

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.
5. 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. The lubricator
should be adjusted to approx 2 drops per minute and SAE 10 oil should be
used.
6. Never exceed the maximum operating pressure for the air tool. Ensure that
air pressure does not exceed that stated in the specification for the tool
when running. Higher pressures and contaminated air will shorten the life of
the air tool due to faster wear and is a possible safety hazard.
INSTALLATION
1. Shut off air pressure from the system.
2. Ensure that the regulator is installed with inlet/outlet air flow in the direction
of the arrow on the regulator body. The regulator should be installed
upstream of lubricator(s), and cycling valve(s) in the air line, and should be
as close as possible to the air tool (s).
3. Fit the mounting bracket to a suitable support, situated in line with the
compressed air supply. Fit the regulator to the mounting bracket from
below and secure with the retaining ring.
4. Remove the blanking plugs from the connection ports and connect to the
supply and delivery lines. Connect air lines using pipe thread sealant tape
on male threads only. When screwing pipes together, prevent ingress of
shavings and sealant to the interior of the unit. Contamination in the unit
may cause it to fail.
5. Make sure that all connections to the regulator are tight and secure.

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6. Install a pressure gauge to either of the gauge ports facing the operator.
The other gauge port should be plugged or can be used as an additional
air outlet for regulated air.
7. It is recommended that an air line filter should be installed upstream of the
regulator.
8. The regulator must be installed in such a way that no mechanical force or
tension occurs and with reasonable accessibility for adjustment and
servicing whenever possible.
9. Your regulator is now ready for use.
OPERATION
1. Ensure that the pressure to the air inlet of the regulator from air line does not
exceed the maximum pressure specified.
2. Before applying inlet pressure, pull the adjustment upwards until you hear
the click, turn it anti-clockwise to release all force on the regulating spring.
Then push the adjustment downwards until you hear the click.
3. Air inlet pressure can be set by turning the adjustment. Pull the adjustment
upwards until you hear the click, turn it clockwise to increase the pressure
or counterclockwise to decrease the pressure. When the desired pressure is
obtained, press the adjustment knob downwards until you hear the click to
secure the adjustment.
• + and - are marked on the knob.
4. The set air pressure can be read on a pressure gauge if fitted.
5. Always approach the desired pressure gradually.
MAINTENANCE
DISASSEMBLY
1. The regulator can be disassembled without removal from air line.
2. Shut OFF the inlet pressure. Reduce pressure in inlet and outlet lines to zero.
3. Turn the adjustment knob fully counterclockwise.
4. Disassemble in accordance with the parts illustrated on page 7.

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CLEANING
1. Clean parts with warm water and soap.
2. Rinse and dry parts. Blow out internal passages in body with clean, dry
compressed air. Inspect parts and replace those found to be damaged.
ASSEMBLY
1. Lubricate the o-rings, bore in bottom plug, valve stem, adjusting screw
threads and tip and the outer circumference and both sides of the thrust
washer with a light coat of good quality o-ring grease.
2. Assemble the unit as shown on page 7.
3. Tighten items listed in the Torque Table.
ACCESSORIES
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 CLARKE International Service Department.
Torque Settings
Part Inch Pounds (N-m)
Screws a & b 25 to 35 (2.8 to 3.9)
Bottom plug 20 to 30 (2.3 to 3.4)

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COMPONENT PARTS
No Description No Description
1 T-handle kit 5 Diaphragm
2 Wall bracket & panel nut 6 Valve assembly
3 Panel nut 7 Bottom plug assembly
4 Universal wall bracket