Clarke X-Pro CAT167 Air Sabre Saw Instruction Manual

SABRE SAW
MODEL NO: CAT167
PART NO: 3120181
OPERATING & MAINTENANCE
INSTRUCTIONS

INTRODUCTION

Thank you for purchasing this CLARKE Sabre Saw, suitable for cutting metal, wood, polymers, and other materials.
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.

SAFETY SYMBOLS

Please read all of the safety and operating instructions carefully before using this product. The following safety symbols are to be found on the machine.

| Read this instruction booklet carefully before use.| ****| Wear ear protection
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| Wear eye protection| |

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 affect your statutory rights.

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 jewelry. 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 a 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 conditions 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 it8. Do not carry out any alterations or modifications to this saw.

8. Always disconnect from the air supply when:
   • Performing any maintenance
   • The saw is not in use.
   • The saw will be left unattended.
   • Moving to another work area.
   • Passing the saw to another person.

9. Never use the saw if it is defective or operating abnormally.

10. Always ensure the saw has stopped before putting it down.

11. The saw should be repaired if required by qualified service personnel.

12. Avoid damaging the saw for example by applying excessive force.

13. ALWAYS maintain the saw with care. Keep it clean for the best and safest performance.

14. Quick change couplings should not be located at the air tool. They add weight and could fail due to vibration.

15. Do not force or misuse the saw. It will do a better and safer job at the rate at which it was designed.

16. Do not remove any labels. Damaged labels should be replaced.

17. 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.

18. Never carry the saw by the air hose.

19. Never carry the saw with your finger on the trigger.

PRODUCT DESCRIPTION

The CAT167 saber saw is a compact and ergonomic tool with a rubber protective grip. It features an adjustable work guide to set cut depths. The blade holder design makes the saw lade installation and replacement fast and easy. The intended use includes cutting mild steel sheets at auto body shops, garages, and other workshops. It is also suitable for cutting reinforced fiberglass, aluminum, wood, etc.

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 meters), 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 airline 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 p 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 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

WARNING: MAKE SURE THAT THE SAW IS DISCONNECTED FROM THE AIR SUPPLY BEFORE INSTALLING, REMOVING, OR REPLACING THE BLADE.
FITTING/REPLACING THE BLADE

1. Loosen the set screw (A) on the blade holder (B) with the hex key (C) provided, by turning counterclockwise.

2. Identify the material and then select the correct blade for your operation.

3. 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.

4. Insert a saw blade (D) into the blade holder as far as it will go.

5. Tighten the set screw (A) with the hex key by turning clockwise. Ensure the saw blade is held tightly to avoid it coming loose.

Loosen the setscrew (E) and adjust the position of the work guide (F) according to the depth of cut required.
CONNECTING THE AIRLINE

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 airline.

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 saber 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 a molded case with auto re-wind:-Part No 3126000
See the latest catalog for details of snap couplings & pressure gauges

OPERATION

OPERATING THE SAW

1. Adjust the work guide as required as shown on page 7.
2. Slide the safety lock forward and squeeze the trigger. Allow the saw to reach full speed before use.
3. 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.
   • Refer to the compressor instruction manual for the procedure to shut down and release the compressed air.
   • Once the pressure has been released, disconnect the air supply hose from the saw. 
   

MAINTENANCE

WARNING: MAKE SURE THAT THE SAW IS DISCONNECTED FROM THE AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE PROCEDURES.
Please note that factors other than the condition of the tool may affect 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.

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 meters), etc.
Contact your CLARKE dealer for further information or  LARKE International Service Department on 01992 565333.
Clarke Air Line Oil (part no. 3050825) is available from your CLARKE dealer
Replacement blades are available  s follows:
3-Pack 18tpi – Part no: 3120184
3-Pack 24tpi – Part no: 3120185
3-Pack 32tpi – Part no: 3120186

TROUBLESHOOTING

pressure on the drill.
2. Motor parts are 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 the air inlet. Allow the oil to soak moving parts before using.
The tool runs slowly. Air flows weakly from the exhaust.| 1. Motor parts jammed with gum/dirt.
2. Regulator in the closed position.
3. General airflow blocked by dirt.| 1. Examine the inlet air filter for cleanliness.
2. Adjust the regulator to an open position.
3. Operate tool in short bursts.
The tool will not run. Air flows freely from the exhaust.| 1. Motor vanes stuck due to buildup of foreign material.| 1. Disconnect air supply and rotate tool assembly manually.
2. Try operating the tool in short bursts.
3. Tap the motor housing gently with a rubber mallet.
4. Drip a few drops of air tool lubricating oil into the air inlet to soak moving parts.
The tool will not shut off.| 1. 0-rings damaged or ill-fitting in the seat.| 1. Return to Clarke dealer for repair.

PARTS DIAGRAM

SPECIFICATION

Please note that the details and specifications contained herein are correct at the time of going to print. However CLARKE International reserves the right to change specifications at any time without prior notice.
DECLARATION OF CONFORMITY

A SELECTION FROM THE VAST RANGE OF

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PARTS & SERVICE:
0208 988 7400
Parts Enquiries
Parts@clarkeinternational.com
Servicing & Technical Enquiries Service@clarkeinternational.com
SALES: UK 01992 565333 or Export 00 44 (0)1992 565335
Clarke INTERNATIONAL Hemnall Street, Epping, Essex CM16 4LG
www.clarkeinternational.com 
Parts & Service: 020 8988 7400
E-mail: Parts@clarkeinternational.com
Service@clarkeinternational.com

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