Clarke air CAT25B Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0315
HIGH SPEED SANDER
MODEL NO: CAT25B
PART NO: 3110404

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INTRODUCTION
Thank you for purchasing this CLARKE Sander.
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.
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 its intended the purpose.
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.
SPECIFICATIONS
Model Number CAT25B
Weight 1.5 kg
Disc Type 100, 114 & 122 mm backing pads
Air Inlet Size 1/4“BSP (female)
Hose size 3/8” ID
Operating Pressure 90 psi (6.2 bar)
Air Consumption 6 cfm average
No Load Speed 18,000 rpm @ 90psi
Sound Pressure Level (LpA dB) 102 dB(A)
Sound Power Level (LpA dB) 110 dB(A)
Vibration Levels 1.9 m/s2

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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 air tool 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 air tool.
4. Do not overreach - Keep proper footing and balance at all times.
5. Never use oxygen, CO2, combustible gases or any type of bottled gas as a
source of power for the tool.
6. Do not connect the air supply hose with your finger on the trigger.
7. Do not exceed the maximum pressure for the tool of 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 use the tool for any other purpose than that described in this
manual.
10. Keep the air supply hose away from heat, oil and sharp edges.
11. Do not fit the tool to any stand or clamping device that may damage it.
12. Do not carry out any alterations or modifications to the tool.
13. Always disconnect from the air supply when:
• Performing any maintenance.
• The tool is not in use.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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• The tool will be left unattended.
• Moving to another work area.
• Passing the tool to another person.
14. Never use the tool if it is defective or operating abnormally.
15. The tool should be serviced at regular intervals by qualified service
personnel.
16. Avoid damaging the tool for example by applying excessive force of any
kind.
17. Always maintain the tool with care. Keep it clean for the best and safest
performance.
18. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
19. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
20. Do not remove any labels. Damaged labels should be replaced.
21. 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.
SANDER-SPECIFIC SAFETY RULES
1. Avoid contact with the moving sanding disc and wear suitable gloves to
protect the hands.
2. Never run the tool unless the abrasive disc is applied to the workpiece.
3. Beware of potentially explosive atmospheres being caused by dust / fumes
resulting from sanding and used dust extraction systems where possible.
4. Always wear a face mask when using the sander as protection from
airborne particles of sanded material. Avoid disturbing existing dust and
minimise the scattering of dust in the workplace environment. Take steps to
control the dust at the point of emission.
TRANSPORTATION AND STORAGE
1. Never carry the tool by the air supply 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 in environments where the temperature is below 0oC.

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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. SAE 10 oil should be
used, and the lubricator adjusted to approx 2 drops per minute.
• 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.
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
When opening the carton for the first time, check against the following list that
all the items are present. Any damage or deficiency should be reported to
your CLARKE dealer immediately.
FITTING THE SANDING DISC
1. Remove the flange nut.
2. Fit the backing disc, ensuring the hole in the disc sits snugly over the
shoulder on the flange nut.
3. Refit the flange nut, finger tight.
• Ensure the shoulder on the flange nut fits inside the hole on the
backing disc.
4. Using the holding tool supplied, to hold the tool and prevent it from turning.
NO DESCRIPTION NO DESCRIPTION
1 Disc Retaining Flange Nut 4 Air Inlet
2Trigger 5LockingRod
3 Air Regulator 6 Backing Disc (x3)

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REPLACEMENT DISCS
NOTE: Common sanding discs with 22 mm bore are used and are
available from a Clarke dealer.
NOTE: IMPORTANT: Only use abrasive sanding pads designed for use with
this type of sanding pad.
CONNECTING THE AIR SUPPLY
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.
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 air inlet or via the hose at the
nearest connection to the air supply.
3. Connect a suitable hose to the air inlet and the other end of the hose to
the compressor.
4. 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).
USING THE SANDER
Squeeze the trigger against the body of the tool to start and evaluate its
speed. The regulator valve can be used for setting positive speed control.
1. To begin work, rest the disc pad on the workpiece and start the sander.
• Let the tool do the work. The actual weight of the sander is normally
sufficient for efficient sanding. Do not put additional pressure on the
sander, which would only slow down the speed of the pad, reducing
efficiency and placing an additional burden on the motor.
2. Gently offer the abrasive disc to work piece, DO NOT FORCE IT, allow the
tool to do the work for which it was designed.
3. Pass the sander back and forth in wide, overlapping areas, taking care to
keep the sander moving around at all times. Avoid dwelling in one place
for more than a moment.
4. Release the trigger to stop the tool.
5. Always ensure the tool has stopped before putting it down.

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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 release the compressed air.
3. Once the pressure has been released, disconnect the air supply hose from
the tool.
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 in-
line mini oiler is not used, this procedure should be repeated after every
two to three hours of use.
CLEANING
1. Keep the body of the tool clean and free from debris.
2. Grit or gum deposits inside the tool may also reduce its efficiency. This
condition can be corrected by cleaning out the air strainer inside the air
inlet, and flushing out the tool with gum solvent or oil, or failing this, the
motor may require dismantling. This is better left to your Clarke dealer.
SERVICE AND REPAIR
If the tool runs erratically or becomes inefficient although the air supply is in
good order, it may be necessary to dismantle the air motor and replace any
worn or damaged parts. Such servicing and repair work should be carried out
by a qualified service technician.
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.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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TROUBLESHOOTING
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.
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
tool and store in a safe, dry place.
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 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
1. Return to Clarke dealer
for repair.

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COMPONENT PARTS
No Description No Description
1Body 16RearEndPlate
2 Control Pin 17 Cylinder
3 Rubber Gasket 18 Vanes
4 Ball 19 Rotor
5 Spring 20 Bushing-Front End
6 Hose Joint 21 Front End Plate
7 Rubber Gasket 22 Spacer
8 O-Ring 23 Bearing
9 Regulator 24 Cylinder Housing
10 Trigger 25 Sanding Adaptor
11 Pin 26 Holding Tool
12 Pin 27 Lock Down Adaptor
13 Housing Lock Ring 28 Backing Plate - 4”
14 Bearing 29 Backing Plate - 4½”
15 Spacer 30 Backing Plate - 5”