Clarke CAT138 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC064
AIR HAMMERS
MODEL NO: CAT138/CAT139
PART NO: 3120152 /3120153

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INTRODUCTION
Thank you for purchasing this CLARKE Air Hammer. 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.
SPECIFICATIONS
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.
CAT138 CAT139
Maximum Operating Pressure 90 psi (6.2 bar)
Air Consumption (under load) 14 cfm 12 cfm
Max Blows per Min. 3300 4500
Air Inlet Size 1/4” BSP thread
Vibration Levels 10.6 m/s2
Sound pressure level 98 dB A
Sound power level 111 dB LWA
Dimensions (L x W x H) 190 x170 x 50 mm 190 x 55 x 150 mm
Weight 2.4 kg 2.2 kg

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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. Always wear ear protectors and a dust mask when using an air hammer.
4. Do not overreach - keep proper footing and balance at all times.
5. Do not fit the tool to any stand or clamping device that may damage it.
6. Never use oxygen, CO2, combustible gases, 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.
7. Do not connect the air hose with your finger on the trigger of the tool.
8. Keep the air supply hose away from heat, oil and sharp edges.
9. Do not exceed the maximum pressure for the tool of 90 psi / 6.2 bar.
10. Check hoses for leaks or excessive wear before use, and ensure that all
connections are secure.
11. Do not use the tool for any other purpose than described in this manual.
12. Do not carry out any alterations or modifications to the tool.
13. 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.
14. This tool should be serviced at regular intervals by qualified personnel.
15. Avoid damaging the tool by applying excessive force of any kind.
16. Always maintain the tool with care. Keep it clean for the best and safest
performance.
17. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
18. 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.
19. Never carry an air tool by the air supply hose.
20. Never carry an air tool with your finger on the trigger.
AIR HAMMER SPECIFIC HAZARDS
1. Only use accessories designed for use with this power tool.
2. Never use any of the chisels supplied as hand struck tool.
3. Never use blunt chisels which require excessive pressure and can break
from fatigue. Always use sharp tools.
4. Never mis-use the tool by prising which can result in a broken tool.
5. Ensure there are no hidden electrical cables, gas pipes etc, which could
cause a hazard if damaged by action of the chisels.
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. The following safety symbols are to be found on the machine.
Keep these instructions in a safe place for future reference.
Read this instruction
booklet carefully
before use.
Wear ear protection
Wear eye protection Wear dust mask.

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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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OVERVIEW
OPERATION
NOTE: Ensure the compressed air supply 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. Read the
instructions supplied with the mini-oiler before use.
NOTE: If a mini-oiler is not being used, insert a few drops of oil into the tool
through the air inlet before use.
NO DESCRIPTION NO DESCRIPTION
1 Retaining spring 3 Air Inlet
2 Trigger 4 Chisel Set (CAT138-5 chisels/
CAT139-4 chisels)

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2. Connect a suitable hose as shown.
3. Connect the other end of the hose
to the compressed air supply.
4. Turn on the air supply and check
for air leaks. Rectify any found
before proceeding.
• PTFE tape may be helpful for
sealing threaded connections.
5. Your air tool is now ready for use.
FITTING THE CHISEL
1. First remove the retaining spring
from the nose by unscrewing it.
• Use the inboard lug to gain
purchase.
2. Insert the chisel into the air
hammer as shown.
3. Replace the retaining spring as
shown.
• Use the lugs to tighten.
USING THE AIR HAMMER
1. Hold the tool firmly, then bring the
tool towards the work at an angle
of approximately 60-70 degrees.
2. Pull the trigger with the chisel in
light contact with the work.
3. Move slowly across the work
surface. To remove scale, rust or
other contaminants, only a light
force should be required.
4. Release the trigger to stop operation, whilst maintaining contact with the
work.
NOTE: that the tool may impact briefly after the trigger is released.
NOTE: The retaining spring has a life expectancy, depending upon the
intensity of usage. It is recommended that you procure a spare
spring for use in the event of failure occurring during the course of
a particular job.

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DISCONNECTING THE AIR SUPPLY
Do not disconnect the air supply hose until the air supply has been shut down
and the compressed air pressure 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.
TROUBLESHOOTING
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.
SYMPTOM PROBLEM SOLUTION
Tool runs slowly or will
not operate.
Dirt or gum in the tool Flush the tool with air line oil
or gum solvent.
Air hose leaks. Tighten and seal hose
fittings with teflon tape.
Low air pressure. Adjust compressor
regulator to 90 psi. Check
the hose is the correct size
and length.
No oil in tool Lubricate the tool.
Worn rotor blades. Return to Clarke dealer for
repair.
Water in airline. Drain air receiver and/or in-
line filter. Run tool until clear
of water. Oil tool again.
Tool will not shut off. O-rings damaged or ill-
fitting in seat.
Return to Clarke dealer for
repair.
Tool runs erratically. Cylinder may have
come loose from the
housing.
Tighten cylinder or return to
Clarke dealer.

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MAINTENANCE
DAILY
1. Before use, drain any water from the compressed air supply.
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 all parts 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, 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-line 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 run the tool in order to lubricate the
internal parts. When not in use, disconnect the tool from the air supply, clean
and store in a safe, dry place.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PARTS LIST & DIAGRAM
No Description No Description
1 Housing 16 Trigger
2 Housing Cover 17 Roll Pin
3Screw 18Plug
4EndCover 19OIlSeal
5Washer 20Pin
6 Rear Plate 21 Pin Cover
7 Valve 22 Spring
8 Set Pin 23 O-Ring
9 Front Plate 24 Air Inlet
10 Piston 25 Muffler
11 Cylinder 26 Screw
12 Retaining Spring 27 Soft Grip-Front
13 Trigger Sleeve 28 Soft Grip-Rear
14 Spring 29 Chisel
15 O-Ring

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DECLARATION OF CONFORMITY