Clarke Air CAT62 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0115
PUNCH & FLANGE TOOL
MODEL NO: CAT62
PART NO: 3110462

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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.

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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.

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• 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.

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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

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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.

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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).

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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.

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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.

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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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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Motor 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. Motor 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. Motor vanes 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.

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PARTS DIAGRAM

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PARTS LIST
No Description No Description
1 Piston 23 Lock-Nut
2 Packing 24 Air Valve Body
3 Back-up Ring 25 O-Ring
4 O-Ring 26 Spring
5 Cylinder 27 Air Valve
6 O-Ring 28 Plug
7 Oil Plug 29 Spring
8 Back-up Ring 30 Valve Cover
9 O-Ring 31 O-Ring
10 Air Inlet 32 Trigger
11 Spring 33 Pin
12 O-Ring 34 Punch
13 Back-up Ring 35 Spring Washer
14 O-Ring 36 Cover
15 O-Ring 37 Guide Sleeve
16 Piston 38 Punching Die
17 Spring 39 Anvil Bed
18 Cylinder 40 Punching Die Bed
19 Piston Rod 41 Packing
20 Washer 42 Screw
21 O-Ring 43 Screw
22 Piston 44 Washer

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SPECIFICATION
Please note that the details and specifications contained herein are correct
at the time of going to print. However Clarke International reserve the right to
change specifications at any time without prior notice.
Model Numbers CAT62
Part Numbers 3110462
Max crimping thickness 1.2 mm (mild steel) / 2mm aluminium)
Hole size 3/16” (4.8mm)
Maximum Operating Pressure 90 psi (6.2 bar)
Air Consumption 0.3 cfm (nominal)
Air Inlet Size 1/4” BSP thread
Vibration Levels <0.8m/s2
Sound Power level 85 dB LWA
Sound Pressure Level 74 dBA
Weight 1.3 kg

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DECLARATION OF CONFORMITY