Clarke CAT125 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC04/20 - ISS 2
GREASE GUN
MODEL NO: CAT125
PART NO: 3120137

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INTRODUCTION
Thank you for purchasing this CLARKE Grease Gun.
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.
4. Keep the air supply hose away from heat, oil and sharp edges.
5. Do not fit the tool to any stand or clamping device that may damage it.
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 botled 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 exceed the maximum pressure for the gun of 90 psi / 6.2 bar.
7. Check hoses for leaks or excessive wear before use, and ensure that all
connections are secure.
8. Do not use the tool for any other purpose than described in this manual.
9. Do not carry out any alterations or modifications to the tool.
10. 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.
11. This tool should be serviced at regular intervals by qualified service
personnel.
12. Avoid damaging the tool for example by applying excessive force of any
kind.
13. Always maintain the tool with care. Keep it clean for the best and safest
performance.
14. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
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
NO DESCRIPTION NO DESCRIPTION
1 Nozzle 5 Air Inlet
2 Air Vent Valve 6 Plunger Handle
3 Grease Inlet Valve 7 Plunger Release Tab
4 Trigger 8 Grease Container

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COMPRESSED AIR REQUIREMENTS
A typical air line layout is shown below. 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. SAE 10 oil should be used and the lubricator adjusted
to approx 2 drops per minute.
.
Use only clean, dry, regulated compressed air as a power source.
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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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 air tool.
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.
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
LOADING WITH GREASE
This air driven grease gun is designed to be loaded in one of three ways:
• Using a standard 400 gram grease cartridge.
• Loading the container with a filler pump.
• Loading the container by bulk filling.
CARTRIDGE LOADING
1. Unscrew the container from the
head of the grease gun.
2. Pull the plunger handle on the
container completely out.
3. Remove any seal or end cap from
the end of the grease cartridge.
4. Insert the grease cartridge all the
way into the container.
5. Re-fit the container to the head of
the grease gun.
6. Press the handle release tab to release the plunger handle.
7. Press the air vent valve to release any excess air trapped inside the gun.
LOADING USING A FILLER PUMP (IF AVAILABLE)
1. Pull the plunger handle on the container completely out.
2. Fit the filler pump to the grease gun inlet valve.
3. Fill the container by pumping the filler pump handle.
4. Disconnect the grease gun inlet valve from the filler pump.
5. Press the handle release tab to release the plunger handle.
6. Press the air vent valve to release any excess air trapped inside the gun.
WARNING: MAKE SURE THE AIR SUPPLY IS DISCONNECTED BEFORE FILLING
THE GREASE CHAMBER.

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BULK FILL LOADING
1. Remove the container from the head of the grease gun.
2. Pull the plunger handle on the container completely out.
3. Fill the container with bulk grease.
4. Re-fit the container to the grease gun.
5. Press the handle release tab to release the plunger handle.
6. Press the air vent valve to release any excess air trapped inside.
OPERATING THE GREASE GUN
1. Connect the gun to the air hose.
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.
2. Squeeze the trigger completely to operate the grease gun.
• The grease is applied in shots, not in a continuous flow.
3. Release the trigger after each shot.
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 to
three hours of constant use.
CLEANING
1. Keep the body and nozzle of the tool clean.
2. 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.
3. 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.
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.
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.
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.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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When not in use, disconnect from air supply, clean and store in a safe, dry
place.
ACCESSORIES
Multi-purpose grease (high melting point Lithium based), 400g cartridge;- part
no 3050875 is available from your Clarke dealer.
A wide range of airline 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 on 01992 565333.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Grease gun fails to work
or is slow.
Air pockets in the gun Draw back the plunger
handle fully and release by
pressing the handle
release. Repeat several
times. This will help to move
the rubber ring into the car-
tridge tube, which essential
for the grease gun to work.
Push the plunger handle all
the way in.
Press the air vent valve
several times to free the air.
Air hose leaks. Tighten and seal hose
fittings with teflon tape.
Low air pressure. Adjust compressor
regulator to 90 psi.
Plunger is sticking. Lubricate plunger.
Cartridge is empty Refill the container tube.
Grease gun is too cold. The gun needs to be at
room temperature(65-80oF)
Gun will not shut off. O-rings damaged or ill-
fitting in seat.
Return to Clarke dealer for
repair.

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PARTS LIST & DIAGRAM
No Description No Description
1 Gun Body 21 Spring
2 Machine screw M4 x 12 22 Spring Seat
3Washer 23Trigger
4 Piston 24 Pin 3*14
5 WAsher 25 Washer
6 Piston Seat 26 Nut M8
7 O-ring 6*1 27 Washer
8 Connector 28 Spring Seat
9Rod 29Spring
10 Spring 30 Cylinder
11 Gun Head 31 Lock
12 Spring Seat 32 Snap Retainer
13 Steel Ball 33 Handle
14 Spring 34 Grease Inlet Seat
15 Grease Nozzle 35 Spring

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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.
16 Switch Lever 36 Rivet
17 O-ring 3.75*1.8 37 Spring
18 O-ring 6.3*1.8 38 Seat
19 O-ring 9*1.8 39 O-ring 3.5*1.5
20 Switch Seat 40 Air Inlet
Model Numbers CAT125
Part Numbers 3120137
Maximum Operating Pressure 90 psi (6.2 bar)
Air Consumption 6 cfm
Capacity 400 gram cartridge
Air Inlet Size 1/4” BSP thread/Euro style quick connector
Vibration Levels <2.5m/s2
Sound power level <70 dB LWA
Dimensions (L x W x H) 485 x 62 x 300 mm
Weight 1.57 kg
No Description No Description

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DECLARATION OF CONFORMITY