Clarke CAT192 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0619 - ISS 1
AIR FILTER/REGULATORS
MODEL NO: CAT192
PART NO: 3120509

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INTRODUCTION
Thank you for purchasing this CLARKE Air Filter/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 Filter/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.
CAT192
Dimensions (D x W x H) 248 x 68 x 60 mm
Air Inlet /Outlet Size 3/8” BSP (female)
Max Flow 120 CFM
Max Inlet Pressure 250 psi
Regulating range 5-150 psi
Element Micron Rating 40μ
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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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 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
Use only clean, dry, regulated compressed air as a power source.
Air compressors must comply with the appropriate European Community
Safety Directives.
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.
If an unusually long air hose is required, (over 8 metres), the line pressure or the
hose inside diameter may need to be increased.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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The air hose must be rated at least 150% of the maximum operating pressure of
the air 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. The lubricator should be adjusted
to approx 2 drops per minute and SAE 10 oil should be used.
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 the air pressure from the air system.
2. Install the filter/regulator vertically with the bowl vertically down. Ensure
that the filter/regulator is installed with inlet/outlet air flow in the direction of
the arrow on the unit.
3. The filter/regulator should be installed upstream of any lubricator and
cycling valve(s) in the air line, and should be as close as possible to the air
tools when used as a main line filter/regulator and/or as a final filter/
regulator.
4. The filter/regulator must be installed in such a way that no mechanical
strain occurs.
5. Fit the mounting bracket to a suitable support, situated in line with the
compressed air supply.
• Ensure sufficient free space above the regulator for future
adjustments.

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6. Note the arrow mark on the regulator body, indicating the direction of air
flow. Connect pipes to the inlet and outlet ports 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. Contaminations in the
unit may cause it to fail.
7. Remove the blanking plugs from the connection ports and connect to the
supply and delivery hoses.
8. 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.
9. Fit the regulator to the mounting
bracket from below and secure
with the retaining ring.
10. Make sure that all connections are
tight and secure.
11. Push the bowl, or bowl with guard, into the filter/regulator body and turn
fully clockwise before pressurizing.
12. Your filter regulator is now ready for use.
USE AND CARE IN SERVICE
1. Ensure that the airline pressure does not exceed 150psi.
2. Air pressure can be set by turning the knob. Pull the knob upwards until you
hear the click, turn it clockwise to increase the pressure or anti-clockwise to
decrease the pressure. When the desired pressure is obtained, press the
knob downwards until you hear the click to secure the setting.
• + and - are marked on the knob.
3. The air pressure set is displayed on the pressure gauge.
4. The filter/regulator is equipped with a manual drain. Turn the manual drain
valve to drain accumulated liquid inside the bowl. Take care to drain the
liquid from the bowl whenever necessary and always keep the liquid
below the baffle.
5. The filter element should be replaced when the pressure drop across the
element exceeds 15 psi. When an excessive pressure drop across a
saturated but uncontaminated element occurs, it may indicate that the
tool being operated exceeds the maximum flow rate (CFM) of the filter/
regulator (See Specifications). Refer to the maximum flow rate of your filter/

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regulator and make sure that the required CFM of the air tool is within the
maximum flow rate of your filter/regulator for best air tool operation.
MAINTENANCE
DISASSEMBLY
1. The filter/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 anti-clockwise.
4. Remove the bowl by pushing into the body and turning counterclockwise.
5. Disassemble in general accordance with the parts illustrated on page 7.
Do not remove the drain unless replacement is necessary. Remove and
replace only if the drain malfunctions or if converting to automatic drain.
CLEANING
1. Clean the plastic bowl with warm water only. Clean other parts with warm
water and soap.
2. Rinse and dry all parts. Blow out internal passages in the body with clean,
dry, compressed air. Blow air through the filter element from inside to
remove surface contaminants.
3. Inspect all parts and replace any found to be damaged.
ASSEMBLY
1. Lubricate all o-rings, adjusting screw threads and tip, outer circumference
and both sides of thrust washer, portion of the manual drain body that
contacts the bowl, hole in the manual drain body that accommodates the
stem of the drain valve and valve stem with o-ring grease.
2. Assemble as shown on page 7 using the torque values listed in the table.
3. Push the bowl into the body and turn fully clockwise.
Torque Settings
Part Inch Pounds (N-m)
Screw (a) & screw (b) 20 to 25 (2.3 to 2.8)
Screw (c) 15 to 30 (1.7 to 3.4)
Baffle, Louvre 10 to 20 (1.1 to 2.3)
Nut 20 to 25 (2.3 to 2.8)

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COMPONENT PARTS
No Description No Description
1 Poly bowl assembly 8 Diaphragm
2 Metal bowl & O-ring 9 Valve assembly
3 Auto drain kit 10 O-ring
4Gauge 11O-ring
5 Neck bracket & nut 12 Sightglass kit
6 Nut 13 Manual drain kit
7 Universal bracket 14 Filter element