Clarke CAT216 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC04/22
3/16”PUNCH & FLANGE TOOL
MODEL NO: CAT216
PART NO: 3110470

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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

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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.

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• 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.

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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 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.

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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.

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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

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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.

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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.

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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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WEEKLY
1. If in regular use, check the air inlet
screen filter for blockage and
clean if necessary.
CLEANING
Grit or gum deposits in the tool may
reduce efficiency.
1. After extensive use, remove the
inlet screen filter and flush out the
mechanism with gum solvent oil or
an equal mixture of CLARKE air-line oil and paraffin. Allow to dry before
use.
2. If the tool still runs erratically or becomes inefficient and the air supply is of
good quality, it may be necessary to dismantle the air motor and replace
worn or damaged parts. You may prefer to take the tool to your CLARKE
dealer if internal maintenance is required.
HYDRAULIC SYSTEM LUBRICATION
1. Remove the oil plug with the hex
key (provided) and set aside.
2. Fill the reservoir with hydraulic oil.
Take care not to overfill.
3. Screw the oil plug back in and
clean any excess oil.
PERFORMANCE
Please note that outside factors may effect the operation and efficiency of
the tool, 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.
Your 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.

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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. Try operating tool in
short bursts.
2. Tap motor housing gently
with a rubber mallet.
3. Drip a few drops of air
tool lubricating oil into air
inlet to soak moving parts
Loss of power or erratic
performance.
1. Excessive drain on
the air hose.
2. Incorrect size or type
of hose connectors.
3. Moisture or restriction
in the air hose/tank
4. Compressor has
insufficient flow
1. Check and confirm that
air hose and fitting is
correct for the air inlet.
2. Do not use multiple hoses
connected together with
quick connecting fittings.
3. Vent system and drain
tank and air hose of
water. Oil tool and run for
1-2 seconds & ensure no
water is evident.
4. Ensure air supply rate
matches tool.
Tool will not shut off. 1. Throttle O-rings
damaged or ill-fitting
in seat.
1. Return to your CLARKE
dealer for repair.

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DECLARATIONS OF CONFORMITY

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COMPONENT PARTS DIAGRAM

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COMPONENT PARTS LIST
ACCESSORIES
A wide range of accessories are available including filter/regulators,
lubricators, high-pressure hoses (5 to 50 metres) etc.
Contact your CLARKE dealer or the CLARKE International Service Department
for further information.
CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
No Description No Description
1 Clamp 23 Trigger
2Setscrew 24Triggerpin
3 Punch die 25 O-ring
4 Guide bush 26 Valve stem
5 Gasket 27 Spring
6 Punch 28 Valve
7Screw 29Spring
8 Plate guard 30 O-ring
9Anvil 31Screw
10 Oil seal 32 Hydraulic piston
11 Bush 33 Bush
12 O-ring 34 O-ring
13 Oil plug 35 Spring washer
14 O-ring 36 Spring
15 O-ring 37 Piston rod
16 Hydraulic cylinder 38 Cushion
17 O-ring 39 Slide plate
18 Bush 40 O-ring
19 Air cylinder 41 Nut
20 Soft grip 42 O-ring
21 Valve body 43 Screw
22 Air inlet 44 Hex key