Clarke air CAT54 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0814
7” ANGLE POLISHER
MODEL NO: CAT54
PART NO: 3110650

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INTRODUCTION
Thank you for purchasing this CLARKE Air Polisher.
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.
Your tool kit 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.
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 tool.
4. Do not operate the tool where there are flammable liquids or gases.
PERSONAL SAFETY
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. Always wear a dust mask when operating this type of tool.
5. Do not overreach - Keep proper footing and balance at all times.
6. Remove any wrench before turning the power tool on. A wrench left
attached to a rotating part of the power tool may result in personal injury.
USE OF AIR POWERED TOOLS
1. Never use oxygen, CO2, combustible gases or any type of bottled gas as a
source of power for the tool.
2. Do not connect the air supply hose with your finger on the trigger.
3. Do not exceed the maximum pressure for the tool of 90 psi / 6.2 bar.
4. Check hoses for leaks or worn condition before use, and ensure that all
connections are secure.
5. Do not use the tool for any other purpose than that described in this
manual.
6. Keep the air supply hose away from heat, oil and sharp edges.
7. Do not fit the tool to any stand or clamping device that may damage it.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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8. Do not carry out any alterations or modifications to the tool.
9. Always disconnect from the air supply when:
• Performing any maintenance.
• The tool is not in use.
• The tool will be left unattended.
• Moving to another work area.
• Passing the tool to another person.
10. Never use the tool if it is defective or operating abnormally.
11. The tool should be serviced at regular intervals by qualified service
personnel.
12. Avoid damaging the tool by applying excessive force of any kind.
13. Always maintain the tool with care. Keep it clean for the best and safest
performance.
14. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
15. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
16. Do not remove any labels. Damaged labels should be replaced.
17. 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.
USE OF THE POLISHING TOOL
1. Try to hold the tool with both hands. Ensure that the workpiece is kept at
waist height where possible. Never use the tool between the legs whilst
sitting on the floor.
2. Always allow the tool to run up to full operating speed before applying it to
the job.
3. Use clamps, or vices to hold a loose workpiece. Failure to secure the
workpiece could result in personal injury.
4. Inspect the pad/mop before use. Do not use if split or torn.
5. Always wear a face mask when using the sander as protection from
airbourne particles. 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.

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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 should be disconnected from the air supply and
stored in a dry place out of the reach of children.
4. Avoid storing the tool in environments where the temperature is below 0oC.
SPECIFICATIONS
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. Always consult the
machine’s data plate.
Model Number CAT54
Dimensions (L x W x H) 330 x 60 x 105 mm
Weight 2.1 kg
Air Inlet Size 1/4“BSP (female)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 5.3 cfm average
No Load Speed 2500 rpm @ 90psi
Sound Pressure Level (LpA dB) 93.3 dB(A)
Sound Power Level (LwA dB) 92.9 dB(A)
Vibration Levels 2.7 m/s2

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OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Polishing disc 5 Trigger
2 Lubrication point 6 2 x Wrenches
3 Regulator 7 Side Handle
4 Air Inlet

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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 AIR
COMPRESSORS AND COMPRESSED AIR SUPPLIES.

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BEFORE USE
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 as shown.
4. Connect the other end of the hose
to the compressor.
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 POLISHING DISC
Thread the polishing disc onto the
drive spindle, followed by the arbor
as shown.
Tighten the arbor using the wrench
with pins (C-spanner) provided while
using the other wrench to prevent
the drive shaft from rotating.
ATTACHING THE BONNET
1. Place the bonnet over the pad so the pad is completely covered.
2. Pull the draw string tight to ensure the bonnet will not slip.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND COMPRESSED AIR SUPPLIES.

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3. Tie the string and tuck the excess back under the edge of the bonnet to
avoid it becoming entangled.
FITTING THE SIDE HANDLE
1. Screw the side handle into either left or right side of the tool body as
required.
OPERATING THE TOOL
The tool should run at a suitable
speed but the speed can be
regulated if required by turning the
regulator on the body of the tool
using suitable screwdrivers.
1. Squeeze the trigger against the
body of the tool.
2. Do not use excess pressure on the
pad as this will shorten its life.
3. Release the trigger to stop the
tool.
• The tool will continue to rotate very briefly after the trigger has been
released.
4. Always ensure the tool has stopped before putting it down.
POLISHING TIPS
• Do not force the polishing pad against the surface.
• Allow the pad to reach working speed before polishing
• Avoid overloading the polisher. If it becomes hot during use, rest for
a few minutes while it cools 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 release the compressed air.
3. Once the pressure has been released, disconnect the air supply hose from
the tool.

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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.
WEEKLY
1. Wash the bonnets after each use by hand and use mild soap with water.
Hang them up to dry.
• Store them flat and allow them to regain shape.
2. Check the air inlet strainer for
blockage and clean if necessary.
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 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.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

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GREASING
The right angle drive is fitted with a
point to provide a facility for
lubrication of the drive gears.
1. After extensive use, apply a shot
of general purpose grease using a
suitable grease gun.
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.
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 tools and store in the
moulded case provided. When storing, ensure the blanking plug is replaced
on the airline connector once the airline is disconnected.
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.

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
tool.
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. 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 LIST
No Part No Description No Part No Description
1 AP-70001 Main Shaft Casing 29 HD-12001 Motor Housing
2 AP-70002 Main Shaft 30 AP-70030 Bushing
3 BB-62011 Ball Bearing 31 VP-70035 Valve Stem
4 AP-70004 Bevel Pinion 32 DG-40058 O-Ring
5 AP-70005 Bearing Support 33 VP-70037 Valve Spring
6 AP-70006 Arbor 34 AP-70034 Air Regulator
7 BB-62032 Ball Bearing 35 ORP-0080 O-Ring
8 AP70008 Bevel Gear 36 ORP-0120 O-Ring
9 AP-70009 Set Nut 37 VP-70C41 Valve Screw
10 ////////// n/a 38 AR-38005 Throttle Lever
11 BB-06082 Ball Bearing 39 SP-25220 Spring Pin
12 BWW-0608 Wave Washer 40 HD-12002 Inlet Bushing
13 AP-70013 Arbor Bearing Cap 41 ORP-0180 O-Ring
14 AP-70014 Distance Nut 42 PG-38043 Plug
15 AP-70015 Internal Gear 43 ORP-0040 O-Ring
16 AP-70016 Idler Spindle 44 ////////// N/A
17 NR-50220 Needle Roller 45 VP-70042 Pad
18 AP-70018 Idler Gear 46 VP-70I43 Pad Nut
19 HD-12022 Washer 47 AP-70C47 Handle
20 BB-60002 Ball Bearing 48 AP-70048 Spacer Collar
21 HD-12019 Front End Plate 49 ///////// N/A
22 HD-12018 Cylinder 50 AG-70057 Wrench (B)
23 AP-70023 Rotor 51 DG-14043 Wrench (A)
24 HD-12016 Rotor Blade K01 HD-12K01 Motor Housing Kit
25 HD-12014 Rear End Plate K02 HD-12K02 O-Ring Kit
26 SP-30060 Spring Pin K03 AP-70K03 Bevel Gear Kit
27 /////////// N/A K04 AP-70K04 Idler Gear Kit
28 VP-70011 Bearing Cap

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PARTS DIAGRAM

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DECLARATION OF CONFORMITY