HIGH SPEED SABRE SAW
Model Nos: CAT32B & CAT97
Part No: 3110426 & 3110853
OPERATION & MAINTENANCE
INSTRUCTIONS
GC11/12
INTRODUCTION
Thank you for purchasing this CLARKE air tool.
Before attempting to use the product, it is essential that you read this manual
thoroughly and carefully follow all instructions given. In doing so you will
ensure the safety of yourself and that of others around you, and you can also
look forward to the product giving you long and satisfactory service.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt 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 its intended purpose.
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.
ENVIRONMENTAL PROTECTION
Do not dispose of this product with general household waste. All tools,
accessories and packaging should be sorted, taken to a re-cycling
centre and disposed of appropriately.
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TABLE OF CONTENTS
INTRODUCTION ......................................................................... 2
GUARANTEE ............................................................................... 2
ENVIRONMENTAL PROTECTION ................................................ 2
TABLE OF CONTENTS .................................................................. 3
SAFETY PRECAUTIONS ................................................................ 4
OVERVIEW .................................................................................. 6
AIR SUPPLY REQUIREMENTS........................... ............................ 7
ASSEMBLY ................................................................................... 8
OPERATION.............................................................................. ....9
TROUBLESHOOTING....................................................................10
MAINTENANCE .......................................................................... 11
PARTS LIST & DIAGRAM...............................................................12
SPECIFICATIONS .................................................................... ... 14
DECLARATION OF CONFORMITY ....................................... ..... 15
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SAFETY PRECAUTIONS
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND /OR DAMAGE TO PROPERTY
WORK ENVIRONMENT
• Keep the work area clean and tidy.
• Dress appropriately - Do not wear loose clothing or jewellery. Tie long hair
out of the way.
• Keep children and visitors away - Do not let children handle the tool.
Make sure that any other persons in the work area are dressed suitably
and are wearing eye and ear protectors.
• Keep the air supply hose away from heat, oil and sharp edges.
• Do not fit the tool to any stand or clamping device that may damage the
tool.
GENERAL USE
• Stay alert and use common sense - do not use the tool when you are tired
or under the influence of alcohol, drugs or medication.
• Always wear eye protection when using the tool - eye protection must
provide protection from the front and the side.
• Always wear ear protectors when using the tool.
• Do not over-reach - keep proper footing and balance at all times.
• Never use any type of bottled gas as a source of power for the tool.
• Do not connect the air supply hose with your finger on the trigger of the
tool.
• Do not exceed the maximum pressure for the tool: 90 psi / 6.2 bar.
• Check hoses for leaks or worn condition before use and ensure that all
connections are secure.
• Do not use the tool for any other purpose than that described in this
booklet.
• Do not carry out any alterations or modifications to the tool.
• Always disconnect from the air supply when:
a)
Performing any maintenance.
b)
The tool is not in use.
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c)
The tool will be left unattended.
d)
Moving to another work area.
• Never use the tool if it is defective or operating abnormally.
• The tool should be serviced as required by your CLARKE dealer.
• Avoid damaging the tool for example by applying excessive force.
• ALWAYS maintain the tool with care. Keep it clean for best and safest
performance.
• ALWAYS ensure the workpiece is firmly secured leaving both hands free to
control the tool.
• ALWAYS ensure the tool has stopped before putting it down after use.
• ALWAYS ensure that any attachments are correctly fastened before
connecting the tool to the power supply.
• Quick change air-line couplings should not be located at the tool. They
add weight and could fail due to vibration.
• DO NOT force or misuse the tool. It will do a better and safer job operating
at the rate for which it was designed.
• Do not remove any labels. Damaged labels should be replaced.
• This tool vibrates during use. Vibration may be harmful to your hands or
arms. Stop using the tool if discomfort, a tingling feeling or pain occurs and
seek medical advice before resuming use.
TRANSPORTATION
• Never carry the tool by the air supply hose.
• Never carry the tool with your finger on the trigger.
STORAGE
• 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).
• Avoid storage in environments where the temperature is below 0oC.
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OVERVIEW
AIR INLET
BLADE
TRIGGER
SAFETY LOCK
The CAT32B and CAT 97 Sabre Saws are ideal for use in garages and
workshops for cutting body panels, exhausts, plastics etc.
The only difference between the two sanders is that the external parts on the
CAT97 are highly polished and include rubber grips. Should you require any
component parts, refer to pages 12 and 13 in the manual and contact your
Clarke dealer.
When unpacking the tool, any damage or deficiency should be reported to
your CLARKE dealer immediately. The carton contains:
•
Heavy Duty Sabre Saw
•
Set of 3 Blades
•
Instruction Manual (this document)
Your sabre saw 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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AIR SUPPLY REQUIREMENTS
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE THOROUGHLY FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE
USE OF COMPRESSORS AND 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 in the air compressor will accelerate wear and
corrosion in the moving parts. 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), line pressure may
need to be increased.
• Never exceed the maximum operating pressure for the tool.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.
• A pressure of 90psi with a flow of 6 cfm is required. Too high an air pressure
will shorten the life of the tool due to excessive wear.
A typical airline layout is shown. If an automatic in-line filter/regulator/
lubricator unit is used it will keep the tool in good condition, but should be
regularly checked and topped up with oil.
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ASSEMBLY
INSTALLING THE BLADE
1. Slide the blade into the saw as
shown.
2. Remove the protective cover by
undoing the screw shown.
3. Secure the blade by tightening
the two hex screws using the hex
key supplied.
SECURING SCREW
CONNECTING THE AIR SUPPLY
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLIES.
Note: Ensure the compressor is turned off.
1. Remove the plastic blanking plug
from the connection port of the
tool.
2. Pour 2-3 drops of CLARKE airline oil
into the air inlet. This should be
done regardless of whether or not
a lubricated air supply is to be
used.
BLANKING
PLUG
3. Connect a suitable hose to the
tool as shown.
4. Connect the other end of the
hose to the compressor. (A whip hose with a quick fit coupling is available
from your CLARKE dealer).
5. Turn on the air supply and check for air leaks. Rectify any found before
proceeding. The tool is now ready for use.
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OPERATION
1. Slide the safety lock forward.
2. Squeeze the trigger
• Allow the saw to reach full speed
before use.
3. Releaase the trigger to stop the
saw. When the blade has
stopped remove it from the
workpiece.
SAFETY LOCK
4. Release the trigger to stop the
tool.
TRIGGER
5. Always ensure the tool has stopped before putting it down.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air pressure released.
2. Once the pressure has been released, disconnect the air supply hose from
the tool.
STORAGE
1. Store the tool safely in its box in a dry, secure environment.
2. When storing, ensure the blanking plug is replaced on the airline
connector once the airline has been disconnected.
3. If the tool is not to be used for longer than 24 hours, run a few drops of
CLARKE airline oil into the air inlet and run the tool for a few seconds to
ensure that the oil has been well distributed throughout the tool.
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TROUBLESHOOTING
SYMPTOM
PROBLEM
Tool runs at normal
1. Motor parts worn.
speed but slows down
under load.
2. Worn or sticking
mechanism due to lack
of lubricant.
Tool runs slowly. Air
1. Motor parts jammed
flows lightly from
with gum &/or dirt
exhaust.
particles.
Tool will not run. Air
flows freely from
exhaust.
SOLUTION
1. Return to dealer for
overhaul.
2. Drip air tool lubricating oil
into air inlet and soak
moving parts.
1. Examine inlet air filter for
cleanliness.
2. Regulator in closed
position.
2. Adjust regulator to open
position.
3. General air flow
blocked by dirt.
3. Operate tool in short
bursts of forward/reverse
rotation.
1. Disconnect air supply &
rotate tool assembly
manually.
1. Motor vanes stuck due
to buildup of foreign
materal.
2. Try operating tool in short
bursts of forward/reverse
rotation.
3. Tap motor housing gently
with rubber mallet.
Tool will not shut off.
1. Throttle O-rings
damaged or not seated
correctly.
4. Drip a few drops of air
tool lubricating oil into the
air inlet to soak moving
parts.
1. Replace O-ring or return
to Clarke dealer for repair.
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MAINTENANCE
WARNING! MAKE SURE THAT THE TOOL IS DISCONNECTED FROM THE AIR
SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.
DAILY
• Drain water from the compressor
air tank and air-line.
• Pour a few drops of CLARKE air
line oil** into the air inlet. This
should be carried out regardless
of whether or not an air line
lubricator is used. If a lubricator is
not used, this procedure should
be repeated after every two to
three hours of use.
Air Inlet Screen
Filter (located
here)
WEEKLY
• Check the air inlet screen filter shown in Fig 4 and clean if necessary.
CLEANING
• Keep the body of the tool clean and free from debris. Grit or gum deposits
in the tool may reduce efficiency.
• After extensive use, remove the inlet screen filter and flush out the
mechanism with gum solvent oil or an equal mixture of SAE No10 oil and
paraffin. Allow to dry before use.
SERVICE AND REPAIR
• Any major servicing and repairs should be carried out by your local
CLARKE dealer or a qualified service technician.
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 line, or the use of connectors of improper size or
poor condition which will reduce air supply.
**Clarke Airline Oil is available from your CLARKE dealer: part no 3050825.
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PARTS LIST
No
Description
No
Description
1
Va l v e S c r e w - C a p
27
Screw
2
O-Ring
28
Housing
3
O-Ring
29
Piston Assembly
4
Air Controller
30
Set Screw
5
Va l v e S p r i n g
31
Hexagonal key (2mm)
6
Va l v e S t e m
32
Guide Plate
7
O-Ring
33
Blade Chuck
7a
O-Ring
34
Work Guide (long/short)
8
Va l v e B u s h
35
Saw Blade 32 teeth
9
Inlet Bush
35
Saw Blade 24 teeth
10
Cap Screw
36
Hexagonal key (4mm)
11
Wa s h e r
38
Screw
12
Lever Hinge Pin
39
Upper Wear Shoe
13
Throttle Lever
40
Blade Guide
15
Valve Body
41
Bridge
16
Bush
42
Front Bumper
17
Cylinder
43
Rear Bumper
18
Valve Sleeve
44
Roll Pin
19
Valve Actuator
45
Spring
20
Washer
46
Packer
21
Cap Headed Screw
47
Packer
22
Gasket
48
Packer
23
Valve Body
49
Set Screw
24
Set Screw
25
Bush
26
Chuck Cover
28a Plastic Cover
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PARTS DIAGRAM
REPLACEMENT BLADES
Replacement blades are available from your CLARKE dealer:
Part no. 3110429
ACCESSORIES
A wide range of accessories are available including filter/regulators,
lubricators, high pressure hoses, etc. Contact your CLARKE dealer for further
information, or call CLARKE International on 01992 565333.
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SPECIFICATIONS
Feature
Specification
Model Number
CAT32
CAT97
Nominal Air Consumption
6 cfm
5 cfm
Operating Air Pressure
90 psi (6.2 bar)
90 psi (6.2 bar)
Air Inlet Size
1/4" BSP
1/4" BSP
Maximum Speed
10,000 strokes/min
10,000 strokes/min
Minimum Hose Size
1/4" (6mm)
1/4" (6mm)
Sound Pressure Level (LPA dB)
92 dBA
Sound Power Level (Lwa Db)
100 dBA
92 dBA
100 dBA
2
Vibration Levels
3.26 m/s
3.26 m/s2
Uncertainty value - k:
9.7 m/s2
9.7 m/s2
Highest measured reading (single plane) 24.9 m/s2
24.16 m/s2
Weight
1.2 kg
0.5 kg
1/4" (6mm)
13 mm
Stroke length
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DECLARATION OF CONFORMITY
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