Clarke 07097A User manual

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MODELS: 07097A, 07127A, 07128A

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Switch Replacement
1-Remove the two screws (13) securing the right handle (42)
2-Remove switch retaining nut (68)
3-Pull switch from handle (Fig. 25)
4-Remove tape from switch to expose wiring connections
5-Disconnect all wires from switch
Assembly Hints
Connect the light wires with the incoming power wires on the switch so that
the light is on when machine is plugged in
Always retape the switch to prevent shorting between metal objects inside
machine
Switch and on/off plate are indexed for proper orientation and should be
installed with the off position to the back
Pigtail Replacement
1-Remove the two screws (13) securing the right handle (42)
2-Disconnect the black and white pigtail wires from the switch and the ground wire (52) from the handle housing
3-Remove pigtail and strain relief assembly (9) from Handle housing
Assembly Hints
Always retape the switch to prevent shorting between metal objects inside machine
Motor Brush Replacement
1-Remove the screw (7) retaining the top cover (25)
2-Disconnect wires from field to brushes
4-Remove the two screws (53) securing each brush holder assembly (56)
5-Push the holder down and over to remove it from the field housing (Fig. 26)
6-Disconnect shunt wire and pull brush (59) out toward the brush side
Speed selection switch replacement
1-Remove four screws (6) securing the cover (19)
2-Remove the switch retaining nut (36)
3-Disconnect wires from switch
Assembly Hints
Black wire from field and diode ground wire connect to the Hi side of switch and the White wire from the field and the diode
terminal wire connect to the Lo side
Diode Replacement
1-Remove four screws (4) securing the field housing (28)
2- Remove field housing assembly by holding the handles and gently tapping down on the lower housing
3-Remove the diode securing nut (33) from inside the housing (Fig. 27)
Assembly Hints
Insulating washers (32) must be intact and installed on both sides of the field housing. The dust baffles can be retained with
super glue to keep them in place while reinstalling the field housing assembly if they were loosened during disassembly.
Fig. 25
Fig. 26
Fig. 27

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Pad Removal and Replacement
1-Remove paper retaining bolt (37)
2-Wedge dust fan with screwdriver or similar object
3-Use spanner wrench (Fig. 28) or punch and hammer (Fig. 29) to remove pad
Note: When replacing the old style steel pad with the new style aluminum the fiber washers between the
pad and lower bearing must be discarded.
Gearbox Removal and Repair
1-Remove pad (35)
2-Remove wall guard
3-Remove three screws (31) from gear cover (29)
4-Press jackshaft (23), gear (22) and bearing (20) assembly out of the cover using the paper retaining
screw to prevent damage to the shaft
5-Remove retaining ring (20) and press the jackshaft out of the gear and bearing
6-Remove retaining ring (25) and press bearing out of the cover
Reassembly
1-Press bearing (27) in cover using outer race only
2-Install seal (26) and Retaining ring (25)
3-Install key (24) and press gear (22) on jackshaft
4-Press bearing (21) on jackshaft using the inner race only
5-Install retaining ring (20)
6-Press the jackshaft assembly into the cover assembly by pressing on the upper end of the jackshaft
while supporting the inner race of the cover bearing
Pinion Gear Removal
1-Remove four screws (4) securing the field housing assembly
2- Remove field housing assembly by holding the handles and gently tapping down on the lower housing
(8)
3-Remove the dust baffles (72)
4-Pry the armature assembly up and out of the lower housing (Fig. 30)
5-Remove retaining ring (78)
6- Use gear puller to remove bearing (76) and pinion gear (77) from armature
Reassembly
NOTE: Lower gearbox assembly must be removed when reinstalling the pinion
1-Press bearing (76) and seal (75) in lower housing (8)
2-Press armature into the lower housing assembly
3-Install key (74)
4-Press pinion gear on armature
5-Reinstall the lower gear housing assembly
Armature Replacement
1-Remove four screws (4) securing the field housing assembly
2- Remove field housing assembly by holding the handles and gently tapping down on the lower housing
(8)
3-Remove the dust baffles (72)
4-Pry the armature assembly up and out of the lower housing (Fig. 30)
5-Remove pinion gear (77) and bearing (76)

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Reassembly
1-Press uper bearing (71) on armature using the inner race only
2-Press bearing (76) and seal (75) in lower housing (8)
3-Press armature into the lower housing assembly
4-Reinstall pinion gear
5-Reinstall dust baffles
6-Reinstall the field housing assembly
Assembly Hints
Pinion and drive gears should always be replaced as sets
It is recommended that the upper and lower armature bearings be replace when installing a new armature
The dust baffles can be retained with super glue to keep them in place while reinstalling the field housing
assembly.
Fig. 28
Fig. 29
Fig. 30

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Symptom
Cause
Repair
Sander will not
turn on
No power at outlet
Check and repair power supply or move to
another outlet
Defective cord or plug
Check continuity and replace defective part
Defective switch
Replace switch
Broken wire or bad connection
on brush holder assembly
Repair or replace brush holder assembly
Extremely worn motor brushes
Replace brushes
Defective armature
Replace armature
Excessive arcing
at motor brushes
Brushes worn
Replace brushes
Broken wire or bad connection
on brush holder assembly
Repair or replace brush holder assembly
Worn or defective armature
Replace armature
Sander bounces
on floor when
sanding
Bent or damaged sanding pad
Dress or replace pad
Poor dust pick-up
Dust bag is over 1/3 full
Empty bag
Dust bag is dirty
Shake debris from bag and wash or replace bag
Obstruction in dust tube
Clear dust tube
Castors adjusted improperly
Adjust castors
Sander continues
to run in low speed
when switched to
high
Two speed switch is defective
Replace switch
Sander continues
to run in high
speed when
switched to low
Two speed switch is defective
Replace switch
Diode is defective
Replace diode

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Plymouth, MN 55447-3408
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