Clarke CAT118 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0220 -rev 1
SABRE SAW
MODEL NO: CAT118
PART NO: 3110874

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INTRODUCTION
Thank you for purchasing this CLARKE Sabre Saw. The CAT118 sabre saw is a
compact and ergonomic tool for cutting steel sheet, reinforced fiberglass,
aluminum, wood, etc, according to the blade being used.
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.
Please keep these instructions for future reference.
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.

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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 drill.
4. Do not operate the saw where there are flammable liquids or gases.
5. Stay alert and use common sense - do not operate the saw when you are
tired or under the influence of alcohol, drugs or medication.
6. Always wear eye protectors when using the saw - Eye protection must
provide protection from flying particles from the front and the side.
7. Always wear ear protectors and face mask when using the saw.
8. Do not overreach - Keep proper footing and balance at all times.
USE OF AIR POWERED TOOLS
1. Never use any type of bottled gas as a source of power for an air tool.
2. Do not connect the air supply hose with your finger on the trigger.
3. Do not exceed the maximum pressure for the saw 90 psi / 6.2 bar.
4. Check hoses for leaks or worn condition before use and ensure that all
connections are secure.
5. Keep the air supply hose away from heat, oil and sharp edges.
6. Do not use this saw for any other purpose than that described in this
manual.
7. Do not fit this saw to any stand or clamping device that may damage it.
8. Do not carry out any alterations or modifications to this saw.
9. Always disconnect from the air supply when:
• Performing any maintenance
• The saw is not in use.
• The saw 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 saw to another person.
10. Never use the saw if it is defective or operating abnormally.
11. Always ensure the saw has stopped before putting it down.
12. The saw should be repaired if required by qualified service personnel.
13. Avoid damaging the saw for example by applying excessive force.
14. ALWAYS maintain the saw with care. Keep it clean for the best and safest
performance.
15. Quick change couplings should not be located at the air tool. They add
weight and could fail due to vibration.
16. Do not force or misuse the saw. It will do a better and safer job at the rate
for which it was designed.
17. Do not remove any labels. Damaged labels should be replaced.
18. This saw vibrates with use. Vibration may be harmful to your hands or arms.
Stop using the saw if discomfort, a tingling feeling or pain occurs. Seek
medical advice before resuming use.
19. Never carry the saw by the air hose.
20. Never carry the saw with your finger on the trigger.

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PRODUCT OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1Blade 4SafetyTrigger
2 Blade securing screw 5 Air inlet
3Safetylock

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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 air 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.
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.

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• Never exceed the maximum operating pressure for the air tool. It is
recommended that air pressure to this tool does not exceed 90 psi
(6.2 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.
BEFORE USE
FITTING THE BLADE
1. Slide the blade into the saw as
shown.
2. Secure the blade by tightening the
grub screw shown using the
hexagonal key supplied.
3. Identify the material and then
select the correct blade for your
operation.
4. Always use the correct saw blade
for the material for smooth and
fast cutting.
• It is recommended that
operators use 32T blades for cutting light sheet metal, body panels,
exhaust pipes, etc., use 24T blades for general purpose sawing
including aluminum and other soft materials, and use 18T blades for
cutting plastic, reinforced fiberglass, wood, etc.
WARNING: MAKE SURE THAT THE SAW IS DISCONNECTED FROM THE AIR
SUPPLY BEFORE INSTALLING, REMOVING OR REPLACING THE BLADE.

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CONNECTING THE AIR LINE
1. Remove the protective plug from
the air inlet and connect a suitable
hose as shown.
2. A gauze filter is fitted within the air
inlet. Ensure this is always in place
and is kept clean. The air line is
connected to the adapter,
preferably via a quick release
coupling (not supplied).
3. Connect the other end of the hose
to the compressed air supply.
4. Ensure the trigger is NOT depressed
when connecting the air line.
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.
6. If required, connect an in-line mini oiler to the airline close to the air tool.
• A mini oiler helps to prolong the life of any air tool.
7. If a mini-oiler is not being used, run a few drops of oil through the air tool
before use. It can be entered through the airline inlet or via the hose at the
nearest connection to the air supply.
• Your sabre saw is now ready for use
• You can fit a whip hose with a quick fit coupling if required
(available from your Clarke dealer.)
USEFUL AIRLINE ITEMS FROM THE CLARKE RANGE
CAT150 Mini-Oiler:- Part No 3120164
8mm Rubber Whip Hose:-Part No 3120104
CAT58 6mm Recoil Hose with 1/4”bsp connectors (25 feet):-Part No 3110458
CAT59 6mm Recoil Hose with 1/4”bsp connectors (50 feet):-Part No 3110459
CRH9 9metres professional recoil hose:-Part No 3120100
CAR20PC Manual Air Hose Reel:-Part No 3126250
CAR15PC PVC hose in moulded case with auto re-wind:-Part No 3126000
See the latest catalogue for details of snap couplings & pressure gauges

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OPERATION
OPERATING THE SAW
1. Slide the safety lock forward and
squeeze the trigger.
• Allow the saw to reach full
speed before use.
2. Release the trigger to stop the
saw. When the blade has stopped
remove it from the workpiece.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the air supply has been shut
down and the compressed air released from the hose.
2. Refer to the compressor instruction manual for the procedure to shut down
and release the compressed air.
3. Once the pressure has been released, disconnect the air supply hose from
the saw.
MAINTENANCE
Please note that factors other than the tools condition 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 connector
DAILY
1. Before use, drain water from the air-line and compressor.
2. Lubricate the saw daily for optimum performance. Use a high quality airline
oil either via a lubricator in the air supply system or by placing a few drops
into the air inlet immediately before use. This should be carried out
regardless of whether or not an in-line lubricator is used.
WARNING: MAKE SURE THAT THE SAW IS DISCONNECTED FROM THE AIR
SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

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CLEANING & OVERHAUL
1. Keep the saw clean and free from debris.
2. If the saw becomes sluggish and the air supply is of good quality, it may be
necessary to replace worn or damaged parts.
3. Grit or gum deposits in the mechanism may eventually reduce efficiency.
This condition can be corrected by cleaning the air inlet filter and flushing
out the saw with gum solvent oil or an equal mixture of SAE No10 oil and
paraffin.
4. Failing this, the saw should be disassembled, thoroughly cleaned, dried
and reassembled. You may prefer to take the saw to your CLARKE dealer if
internal maintenance is required.
STORAGE
If the saw 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 saw should be disconnected from the air supply and
stored in a dry place out of the reach of children. Avoid storing in a damp
environment.
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.
Clarke Air Line Oil (part no. 3050825) is available from your CLARKE dealer
Replacement blades are available as follows:
Part no. 3110429

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
drill.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force
applied to the drill.
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. O-rings damaged or
ill-fitting in seat.
1. Return to Clarke dealer
for repair.

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PARTS DIAGRAM

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COMPONENT PARTS
No Description No Description
1 Blade 20 Pin
2 Bearing housing 21 Trigger pin
3 Bolt 22 Spring
4 Blade chuck 23 Trigger
5 Spring 24 Bolt
6 Cylinder cap 25 Bolt
7 O-ring 26 Valve stem seat
8 Piston 27 O-ring
9 Piston blade 28 O-ring
10 Spring 29 O-ring
11 Safety nozzle 30 Valve stem
12 Bolt 31 Spring
13 Safety set 32 O-ring
14 Bolt 33 Valve stem housing
15 Housing 34 O-ring
16 Rubber grip 35 Screw cap
17 Cylinder 36 Washer
18 Gasket 37 Air inlet plug
19 End cap

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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 CAT118
Part Number 3110874
Recommended Hose Size (ID) 10 mm (3/8”)
Air Inlet Size 1/4“ bsp female
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption (Average) 6 cfm (169 l/min)
Max Speed 5000 strokes/min @ 90psi
Sound Pressure Level (LpA dB) 82.9 dB(A)
Sound Power Level (LwA dB) 93.9 dB(A)
Vibration Levels 3.5 m/s2
Vibration Uncertainty K: 0.63 m/s2
Weight 0.95 kg
Dimensions (LxWxH) 255 x 41 x 81 mm

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DECLARATION OF CONFORMITY