Clarke X-PRO CAT140 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0414
AIR SHEAR
MODEL NO: CAT140
PART NO: 3120154

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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 are to 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.
USE OF POWER 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 shear. 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. Keep the air supply hose away from heat, oil and sharp edges.
8. Do not fit the tool to any stand or clamping device that may damage it.
9. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
10. Do not use the tool for any purpose than that 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.
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 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
NO DESCRIPTION NO DESCRIPTION
1 Moving Knife 4 Airline Connector
2 Side Blade 5 Hex Key
3Trigger

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COMPRESSED AIR REQUIREMENTS
• 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 and topped up with oil. clarke airline oil should
be used, and the lubricator adjusted to approx 2 drops per minute.
• For optimum performance it is recommended that a 3/8” ID hose is
used.
• 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 dirty air will shorten
the life of the tool due to faster wear and is a possible safety hazard.
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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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, using the airline connector supplied
with the tool.
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. PTFE tape may be useful for sealing threaded connections.
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 SUPPLIES.

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OPERATION
USING THE SHEAR
1. Place the shear against the side
of the sheet metal you want to
cut, see below.
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 to stop the
metal shear.
5. Always ensure the tool has stopped before putting it down.
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
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released.
2. Refer to the compressor instruction manual for the procedure to shut down
and vent the compressed air.
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.

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MAINTENANCE
DAILY
1. Before use, drain water from the airline filter and compressor.
2. Pour a few drops of Clarke air-line oil, into the tool air inlet. 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 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 or oil, or failing this, the tool should be
disassembled, thoroughly cleaned, dried and reassembled. This is better
left to your Clarke dealer.
3. After extensive use, remove the inlet screen filter and flush out the
mechanism with gum solvent or oil or an equal mixture of Clarke air-line 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.
WARNING: MAKE SURE THAT THE AIR 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.
When not in use, disconnect from air supply, clean & store in a safe, dry place.
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.
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.
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. 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. 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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PARTS LIST
No Description No Description
1 Housing 24 Cylinder
2 Housing Cover 25 Bolt
3Screw 26FrontPlate
4RearCover 27Gasket
5Bolt 28Bearing
6 Soft Grip 29 Bearing
7 Soft Grip 30 Gear
8 Exhaust Deflector 31 Bolt
9 Screw 32 Work Spindle
10 Air Inlet 33 Ring Gear
11 O-Ring 34 Bearing
12 O-Ring 35 Clamp Nut
13 O-Ring 36 Spacer
14 Valve Stem 37 Eccentric Nut
15 O-Ring 38 Bearing
16 Trigger Sleeve 39 Cutter Housing
17 Spring 40 Socket Headed Screw
18 Trigger 41 Lock Nut
19 Set Screw 42 Left Blade
20 Bearing 43 Knife
21 Rear Plate 44 Pivot Bush
22 Rotor 45 Right Blade
23 Rotor Blade (set 5) 46 Hex key

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PARTS DIAGRAM

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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 Number CAT140
Part Number 3120154
Min. Hose Size (ID) 3/8” BSP
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption 18 cfm at full power (average = 5.5 cfm)
Stroke per min 3200 @ 90psi
Air Inlet Size 1/4“ BSP
Sound Pressure Level (LpA dB) 79 dB(A)
Sound Power Level (LwA dB) 90 dB(A)
Vibration Levels 4.2 m/s2 (uncertainty factor K= 1.5m/s2)
Weight 1.5 kg
Cutting Capacity 1.2 mm (18 gauge) mild steel

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DECLARATION OF CONFORMITY