Clarke CAT50 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0414
AIR SHEARS
MODEL NO: CAT50 & 106
PART NO: 3110550 & 3110862

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INTRODUCTION
Thank you for purchasing this CLARKE Air Shear.
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.
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. The following safety symbols may be found on the air tool.
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.
Read this instruction
booklet carefully
before use.
Wear ear protection
Wear eye protection

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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.
4. Do not operate the tool where there are flammable liquids or gases.
5. Keep the air supply hose away from heat, oil and sharp edges.
6. Do not fit the tool to any stand or clamping device that may damage it.
USE
1. Stay alert and use common sense - do not operate the shear 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.
3. Always wear ear protectors when using the shear.
4. Do not overreach - Keep proper footing and balance at all times.
5. Never use any type of bottled gas as a source of power for the shear.
6. Do not connect the air supply hose with your finger on the trigger.
7. Do not exceed the maximum pressure for the tool 90 psi / 6.2 bar.
8. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
9. Do not carry out any alterations or modifications to the tool.
10. Always disconnect from the air supply when:
• Performing any maintenance
• The tool is not in use
• The drill will be left unattended
• Moving to another work area
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• Passing the tool to another person.
11. Never use the tool if it is defective or operating abnormally.
12. Never use the tool if it is defective or operating abnormally.
13. This tool should be serviced at regular intervals by qualified service
personnel.
14. Avoid damaging the tool for example by applying excessive force of any
kind.
15. Always maintain the tool with care. Keep it clean for the best and safest
performance.
16. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
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. Do not remove any labels. Damaged labels should be replaced.
19. 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 SHEARS
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 cutting operation.
4. Do not use damaged blades. When replacing blades make sure they are
correctly and securely mounted.
5. Anticipate the unexpected tool movement due to a binding blade.
Release the trigger immediately if this occurs.
TRANSPORT & STORAGE
1. Never carry the tool by the air hose.
2. Never carry the tool with your finger on the trigger.
3. 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).
4. Avoid storing the tool where the temperature is below 0oC.

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OVERVIEW
The CAT50 and CAT106 differ only by virtue of the CAT106 having a polished
metal casing as opposed to a painted finish.
NO DESCRIPTION NO DESCRIPTION
1 Moving Knife 4 Airline Connector
2 Side Blade 5 Hex Key
3Trigger

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THE COMPRESSED AIR SUPPLY
• Use only clean, dry, regulated compressed air as a power source.
• Air compressors used with the impact wrench 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 impact wrench. 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 and topped up with oil. SAE 10 oil should be
used, and the lubricator adjusted to approx 2 drops per minute.
• The minimum hose diameter should be 5/16”(8mm) ID and fittings
should have the same internal dimensions.
• 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.

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BEFORE USE
NOTE: Ensure the compressor 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. Remove the
oil fill screw from the side of the
mini oiler and fill with Air-line Oil
available from your CLARKE
dealer. Replace the screw
before using the tool.
2. 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 strainer or via the hose at the nearest connection to the air supply.
3. Connect a suitable hose as shown.
4. Connect the other end of the hose to the compressor.
5. Turn on the air supply and check for air leaks. Rectify any found before
proceeding.
6. 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 COMPRESSED AIR SUPPLY.

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OPERATION
OPERATING THE AIR SHEAR
1. Place the cutter head against the
side of the sheet metal you want
to cut.
2. Squeeze the trigger to start the
metal shear.
3. Maintain constant pressure to
move the tool through the sheet
metal.
4. Release the trigger switch to stop
the metal shear.
WORKING AT AN ANGLE
The shears can be set to operate in
line with the handle or at an angle, for
example, if working in a confined
space.
1. To do this, re-set the nose section in
its new position by slackening the
hex screw shown using the key,
and rotating the nose assembly to
the angle required.
• It can be set at any angle
required.
2. Ensure you have re-tightened the screw before using the shear.
DISCONNECTING THE AIR SUPPLY
Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air 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 drill.
3. Store the tool safely in its box in a dry, secure environment.

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MAINTENANCE
DAILY
1. Before use, drain water from the air tank, air line and compressor.
2. Pour a few drops of CLARKE airline oil, into the air inlet. This should be
carried out regardless of whether or not an in-line mini oiler is used. If an
inline mini oiler is not used, this procedure should be repeated after every
two to three hours of use.
WEEKLY
1. Check the air inlet screen filter for
blockage and clean if necessary.
CLEANING
1. Keep the body of the tool clean
and free from debris.
2. Grit or gum deposits in the tool
may also reduce efficiency. This
condition can be corrected by
cleaning the air strainer and
flushing out the tool with gum solvent oil, or failing this, the tool should be
disassembled, thoroughly cleaned, dried and reassembled.
3. 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.
4. Clean the air inlet filter screen inside the hose adaptor.
5. If the tool 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.
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.
WARNING: MAKE SURE THAT THE TOOL IS DISCONNECTED FROM THE AIR
SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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REPLACING BLADES
After heavy use, the blades and knife
may become damaged and require
replacement. Replacements are
available from your Clarke dealer.
1. To remove both blades and the
knife, unfasten the three socket
headed screws using the hex key
provided.
• The nose section will become
detached from the body
connector.
2. Remove and replace the knife and the left/right-hand blades and re-
tighten the screws.
• Take care not to lose the knife pivot bush shown and replace it when
refitting the knife.
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 for 5 seconds in order to
lubricate the internal parts.
When not in use, disconnect from air supply, clean & store in a safe, dry place.
ACCESSORIES
A wide range of accessories is available including filter/regulators, lubricators,
high-pressure hoses (5 to 50 metres) etc.
Contact your CLARKE dealer for further information or CLARKE International
Service Department on 01992 565333.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
tool.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force
applied to the tool.
2. Return to Clarke dealer
for repair.
3. 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. Regulator in closed
position.
3. General airflow
blocked by dirt.
1. Examine inlet air filter for
cleanliness.
2. Adjust 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. Disconnect air supply
and rotate tool assembly
manually.
2. Try operating tool in
short bursts.
3. Tap motor housing gently
with a rubber mallet.
4. Drip a few drops of air
tool lubricating oil into air
inlet to soak moving
parts.
Tool will not shut off. 1. Throttle O-rings
damaged or ill-fitting
in seat.
1. Return to Clarke dealer
for repair.

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SPECIFICATION
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.
Model Numbers CAT50 CAT106
Part Numbers 3110550 3110862
Min. Hose Size (ID) 8 mm
Operating Pressure 90 psi (6.2 bar)
Air Consumption 4 cfm 3 cfm
Cutting Speed 15 ft/min (4.57 m)
Width of Cut 5.5 mm
Cutting Capacity 1.6 mm (16 gauge) 1.2 mm
Strokes per minute 2600 2500
Air Inlet Size 1/4“ BSP
Sound Pressure Level (LpA dB) 88.1 dB(A)
Sound Power Level (LwA dB) 99.6 dB(A)
Vibration Levels <2.5 m/s2
Weight 1.1 kg 1.19 kg
Dimensions (L x W x H) 205 x 50 x 140 mm

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PARTS LIST & DIAGRAM

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DECLARATION OF CONFORMITY
No Description No Description
1 Motor Housing 21 Cylinder
2 Set Screw 22 Front End Plate
3 Roll Pin 23 Ring Gear
4 Exhaust Deflector 24 Idler Gear
5 Screw 25 Idler Gear Bushing
6 O-Ring 26 Idler Gear Plate
7 Valve Stem 27 Ball Bearing
8 O-Ring 28 Lock Nut
9 O-Ring 29 Air Inlet
10 O-Ring 30 Nut
11 Valve Bushing 31 Ball Bearing
12 Trigger 32 Cutter Housing
13 Set Screw 33 Machine Screw
14 Bearing Cap 34 Lock Nut
15 Spring 35 Left Blade
16 Ball Bearing Race 36 Spacer
17 Rear End Plate 37 Centre Blade
18 Pin 38 Right Blade
19 Rotor 39 Housing Sleeve
20 Rotor Blade

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DECLARATION OF CONFORMITY