Clarke air CAT49 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0714
LONG BED SANDER
MODEL NO: CAT49
PART NO: 3110535

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INTRODUCTION
Thank you for purchasing this CLARKE Long Bed Sander. The CAT49 Sander is
ideal for use in garages and workshops. The reciprocating (non-orbital) action
is ideal for flatting over large areas.
When unpacking the tool, any damage or deficiency should be reported to
your CLARKE dealer immediately.
Your sander has been designed to give long and trouble free service. If,
however, having followed the instructions in this booklet carefully. 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.
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 CAT49
Part Number 3110535
Min. Hose Size (ID) 3/8” BSP
Max Operating Pressure 90 psi (6.2 bar)
Air Consumption average 8 cfm
Max No Load Speed 2,100 strokes/min @ 90psi
Air Inlet Size 1/4“BSP
Sound Pressure Level (LpA dB) 91 dB(A)
Sound Power Level (LwA dB) 104 dB(A)
Uncertainty Factor 3 dB
Vibration Levels 8.4 m/s2 (uncertainty factor K= 1.5 m/s2)
Weight 2.8 kg
Sanding Pad Size 70 x 400 mm

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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 sander 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 sander. 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. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
8. Keep the air supply hose away from heat, oil and sharp edges.
9. Do not use the tool for any purpose than that described in this manual.
10. Do not fit the tool to any stand or clamping device that may damage it.
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 personnel.
15. Avoid damaging the tool 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.
SANDER-SPECIFIC SAFETY RULES
1. Avoid contact with the moving sanding pad and wear suitable gloves to
protect the hands.
2. Never run the tool unless the abrasive pad 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
airbourne particles of sanded material. Avoid disturbing existing dust and
minimise the scattering of dust in the worplace environment. Take steps to
control the dust at the point of emission.
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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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
CONNECTING THE AIR SUPPLY
1. Pour 2-3 drops of CLARKE airline oil into the air inlet. This should be done
regardless of whether or not a lubricated air supply is to be used.
2. Connect a suitable hose to the tool as shown using the airline connector
supplied with the tool.
3. 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.
4. 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.
5. Connect the other end of the hose to the compressor.
6. Turn on the air supply and check for air leaks. Rectify any found before
proceeding. PTFE tape may be useful for sealing threaded connections.
7. 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.)
FITTING THE SANDING SHEET
• The CAT49 sander requires
70 x 400mm abrasive sheet
Fold the sheet around the
end of the bed and grip it
in position with the spring
clip at each end. Take care
that it is positioned
centrally.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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OPERATING
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 machine is
normally sufficient for efficient sanding. Do not put additional
pressure on the machine, which would only slow down the speed of
the pad, reducing efficiency and placing an additional burden on
the motor.
2. 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.
3. Release the trigger to stop the tool.
4. Always ensure the tool has stopped before putting it down.
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.
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.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

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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. 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.
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.
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
When not in use, disconnect from air supply, clean & store in a safe, dry place.
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.

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TROUBLESHOOTING
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.
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 shor 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 DIAGRAM
No Part No Description No Part No Description
1 561601 Hose Adaptor 19 561619 Actuator Gear
2 561602 Rear Head 20 561620 Front Head
3 561603 Packing 21 561621 Socket cap Screw
4 561604 Valve 22 561622 Knob Assembly
5 561605 O-Ring 23 561623 Adj. Shaft
6 561606 O-Ring 24 561624 Plunger
7 561607 Socket Screw 25 561625 Cross head Screw
8 561608 Switch Control Valve 26 561626 Trigger
9 561609 O-Ring 27 561627 Handle
10 561610 Spring 28 561628 Roll Pin

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DECLARATION OF CONFORMITY
11 561611 Body Assembly 29 561629 Flat Head Screw
12 561612 Piston Ring 30 561630 SideStrip
13 561613 Piston 31 561631 Cross head Screw
14 561614 Wear Button 32 561632 Carrier Assembly
15 N/a N/A 33 561633 Cross head Screw
16 561616-1 Shaft (9.5mm) 34 561634 Pad Assembly
17 561617 Gear 35 561635 Hex Nut
18 561618 Actuator Valve
No Part No Description No Part No Description