Clarke CAT 151, 3120165 User guide

AIR/HYDRAULIC RIVETER

MODEL NO: CAT151

PART NO: 3120165

OPERATING & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0622 Rev 2

INTRODUCTION

Thank you for purchasing this CLARKE Air Riveter.

The CAT151 Air Riveter is supplied with 4 nose pieces to accept 2.4 mm, 3.2
mm, 4.0 mm and 4.8 mm rivets. The riveter has a hardened steel jaw assembly,
a rivet stem safety cap, and is suitable for both aluminium and steel rivets.

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.

OPERATING PRINCIPLE

The rivet is pushed through the hole in the workpiece and the rivet pin inserted
into the rivet gun nosepiece which will grip it tightly.

When the rivet gun is activated the throttle valve allows compressed air
through the tool. The pressure of the air forces the rivet pin into the jaws which
pull the pin up into the rivet. As the pin is taken up, the base of the rivet
expands and this joins the workpiece. The rivet gun pulls the pin until it breaks
off, thereby securing the rivet. The used pins are ejected into the safety cap
for disposal.

Pop rivets have limited strength so they are typically used for fastening light
sheet metals. Professionals sometimes refer to these rivets as blind rivets, as the
user cannot see the other side of the material being riveted.

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.

2

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

GENERAL SAFETY RULES

CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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 an air tool. This product should only be used with a
suitably rated compressed air supply.

5. Do not connect the air hose with your finger on the trigger of the riveter.

6. Do not fit the air tool to any stand or clamping device that may damage it.

7. Do not exceed the maximum pressure for the tool of 7 bar.

8. Keep the air 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.

• Never use the tool if it is defective or operating abnormally.

3

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

13. This air tool should be serviced at regular intervals by qualified service
personnel.

14. Avoid damaging the air tool by applying excessive force of any kind.

15. Always maintain the air tool with care. Keep it clean for the best and safest
performance.

16. Do not force or misuse the air tool. It will do a better and safer job at the
rate for which it was designed.

17. Do not use the riveter if the safety cap is not in place.

18. Do not point the air tool at people or animals.

TRANSPORTATION

1. Never carry an air tool by the air hose.

2. Never carry an air tool with your finger on the trigger.

4

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

OVERVIEW

NO DESCRIPTION NO DESCRIPTION

1 Nosepiece (2.4, 3.2, 4.0 & 4.8 dia) 7 1/4” BSP Air Inlet Connection

2 Outer Cylinder 8 Trigger

3 Hanging Ring 9 Spanner

4 Safety Cap 10 Spanner Gauge

5 Retaining ring for safety cap 11 Large and Small O-rings (see p11)

6 Air Cylinder 12 Air Filter

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

5

COMPRESSED AIR REQUIREMENTS

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.

• 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 7 bar 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.

6

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

PREPARATION & ADJUSTMENT

FILLING/CHECKING THE OIL LEVEL

Before use, check that the rivet gun is topped up with hydraulic oil (not
supplied) after removing the cylinder cap and piston assembly to ensure that
it is properly lubricated.

1. Disconnect the riveter from the air
line.

2. Hold upside-down and remove the
air cylinder cap (fig 1) with the
spanner provided.

3. Remove the air/hydraulic piston
assembly (grip the exposed nut
and pull up) as in Fig 2.

4. Add hydraulic oil to the hydraulic
cylinder until the level is just below
the connection with the air
cylinder. See fig. 3.

• Hydraulic oil is avaialble from

your Clarke dealer: part No
3050830 (1 litre).

5. Lightly lubricate the inner wall of
the air cylinder.

6. Replace the air/hydraulic piston
assembly and press in as far as it will go.

7. Refit and tighten the air cylinder cap.

CHECKING/ADJUSTING THE STROKE

1. Check that the hydraulic oil level is
correct as above.

2. Remove the outer cylinder using
the spanner provided.

7

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

3. Check the jaw stroke by using the
spanner/gauge as in figs 5 and 6.

4. Set the distance to < 70 mm i.e. the
length of the spanner gauge as
shown.

5. If necessary, adjust the stroke as
follows:

• Hold the rear jaw case (fig 7)

with the larger spanner and
loosen the lock nut with the
spanner/gauge.

• Adjust the stroke by rotating the

jaw case assembly and
tightening the lock nut when
adjustment is complete.

6. Refit the outer cylinder.

CONNECTING THE AIRLINE

NOTE: Ensure the air compressor is turned off.

1. Remove the protective plug from
the air inlet port and connect a
suitable hose as shown.

2. Connect the other end of the hose
to the compressor.

3. Turn on the air supply and check
for air leaks. Rectify any leaks
found before proceeding.

• PTFE tape may be helpful for

sealing threaded connections.

4. If required, connect an in-line mini oiler into the air supply line to the tool.

• A mini oiler helps to prolong the life of the air tool.

• 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.

8

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

5. Turn the compressor back on and set the regulator to 6.3 to 7 bar. Do not
exceed this pressure.

6. Your air riveter is now ready for use.

• You can fit a whip hose with a quick fit coupling if required

(available from your Clarke dealer).

OPERATION

WARNING: ALWAYS FIT THE SAFETY CAP TO THE REAR OF THE FRAME
BEFORE USE TO PREVENT INJURY FROM EJECTED RIVET STEMS. FIT WITH THE
SLOT FACING DOWNWARDS SO THAT THE STEMS FALL TO THE FLOOR.

1. Select the nosepiece to suit the rivet size and fit it to the head using the
spanner.

2. Insert the rivet stem fully through the nosepiece and into the jaws.

3. Press the rivet body through the pre-drilled hole in the workpiece and hold
the rivet flange flush against the workpiece. Always take care to drill the
holes with the same size drill bit as the rivets to be used.

4. Squeeze the trigger.

• The rivet will be compressed and the rivet stem will be ejected into

the safety cap from where they can be collected for disposal.

DISCONNECTING THE AIR SUPPLY

1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released.

2. Squeeze the trigger to discharge any compressed air from the riveter.

3. Once the pressure has been released, disconnect the air supply hose from
the air tool.

4. Store the tool safely in its box in a dry, secure environment.

9

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

MAINTENANCE

WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

DAILY

1. Before use, drain water from the air-line and compressor.

2. Maintain the tool with care. Keep it oiled for optimum performance.

3. Lubricate the air tool daily with a high quality air tool oil either via an oiler in
the air supply system or by placing a few drops into the riveter air inlet
immediately before use. 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.

CLEANING

1. Keep 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.

CHANGING JAWS

1. Disconnect the tool from the air
line.

2. Remove the outer cylinder (fig 9)
using the spanner provided.

3. Use both spanners to unscrew the
front jaw case (fig 10) from the rear
jaw case.

4. Remove the jaws and clean with
solvent and brush. If the teeth are
blunted, replace with new jaws.

Reverse the above procedure to reassemble.

10

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

OTHER REPLACEMENT PARTS

The CAT151 is supplied with two replacement O-rings shown as items 15 and
24/25 on the parts list and diagram. Suitable spanners will be required to
disassemble the riveter. If difficulty is found take the riveter to your Clarke
dealer for this operation.

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 tool 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, the tool must be disconnected from the air supply and stored
in a dry place out of the reach of children.

Avoid storing in cold or damp environments.

ACCESSORIES AND CONSUMABLES

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.

Rivet Size (Pack of 100) Clarke Part No

Rivets are avaiable for the
CAT151 in the following
sizes.

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

3.2 x 6.0mm 3111770

3.2 x 10.2mm 3111775

3.2 x 16.5mm 3111780

4.0 x 6.4mm 3111785

4.0 x 11.0mm 3111790

4.0 x 16.0mm 3111795

4.8 x 6.4mm 3111800

4.8 x 9.6mm 3111805

4.8 x 16.0mm 3111810

11

SPECIFICATION

Model Numbers CAT151

Rivet Capacity 2.4, 3.2, 4.0 & 4.8 mm dia

Operating Pressure 6.3 bar

Maximum Operating Pressure 7 bar

Air Consumption 0.03 cfm average

Traction Power 720 kg

Air Inlet Size 1/4” BSP female thread

Vibration Levels

Uncertainty Factor (K) 1.5

Sound Power Level 97 dB LWA

Sound Pressure Level 86 dBA

Uncertainty Factor (K) 3.0

Dimensions (L x D x H) 230 x 81 x 290 mm

Weight 1.9 kg

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.

2.45 m/s

2

12

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

DECLARATIONS OF CONFORMITY

13

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

PARTS LIST

No Description No Description

1A Nosepiece (4.8mm - 3/16”) 26 Bush

1B Nosepiece (4mm - 5/32”) 27 Trigger

1C Nosepiece (3.2mm - 1/8”) 28 Trigger Pin

1D Nosepiece (2.4mm - 3/32”) 29 Rod Pin

2 Socket head 30 Trigger Rod

3 Jaw Case 31 Trigger Lever

4 Jaw Case Joint 32 Rod Pin

5Jaws 33Lever Pin

6 Jaw Pusher 34 Air Cylinder

7 Jaw Pusher Spring 35 Valve Pusher O-Ring

8 Jaw Case Washer Ring 36 Brass Valve Pusher

9 Jaw Case Lock Nut 37 Valve Pusher Spring

10 O-ring 38 Valve Pusher Brass Collar

11 O-ring 39 Valve Pusher O-Ring

12 Back-up ring 40 Valve

13 Housing 41 Valve Spring

14 Oil Piston 42 Valve cap O-Ring

15 Oil Piston O-ring 43 Valve cap

16 Oil Piston Back-up Ring 44 Frame Lock Nut

17 Return Spring A 45 Air Piston Stem

18 Return Spring B 46 Rubber Cushion

19 Hanging Ring 47 Air Piston O-Ring

20 Housing Cap 48 Air Piston

21 Safety Cap 49 Air Piston Locknut

22 Housing Cap Nut 50 Air Cylinder O-Ring

23 Spacer 51 Air Cylinder cap

24 U-type ring 52 Spanner Gauge (17/14 mm)

25 O-Ring 53 Spanner (10/15/24 mm)

14

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

PARTS DIAGRAM

15

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]