Clarke CAT111 Installation and operation manual

ORBITAL SANDER
Part Nos: 3120126
GC0409
MODEL No: CAT111
OPERATING & MAINTENANCE
INSTRUCTIONS

2
INTRODUCTION
Thank you for purchasing this CLARKE product.
Before attempting to use the sander, 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 the
sander giving you long and satisfactory service.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt 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.
ENVIROMENTAL PROTECTION
Do not dispose of this product with general household waste. All tools,
accessories and packaging should be sorted, taken to a recycling
centre and disposed of appropriately.
PARTS & SERVICING
For parts & Servicing, please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]

3
CONTENTS
Introduction ............................................................................................ 2
Guarantee .............................................................................................. 2
Environmental Protection ...................................................................... 2
Parts & Service Contacts ....................................................................... 2
Technical Specification ......................................................................... 3
General Safety Precautions .................................................................. 4
Overview ................................................................................................ 7
Assembly ................................................................................................ 7
Operating Instructions ........................................................................... 8
Troubleshooting ...................................................................................... 9
Maintenance ........................................................................................ 10
Parts Lists and Diagrams ..................................................................... 11
Vibration Emissions .............................................................................. 13
Declaration of Conformity .................................................................. 15
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.
TECHNICAL SPECIFICATION
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4
SAFETY PRECAUTIONS
WORK ENVIRONMENT
• Keep the work area clean and tidy.
• Dress appropriately - Do not wear loose clothing or jewellery. Tie long hair
out of the way.
• Keep children and visitors away - Do not let children handle the sander.
Make sure that any other persons in the work area are dressed suitably
and are wearing eye and ear protectors.
• Keep the air supply hose away from heat, oil and sharp edges.
• Do not fit the sander to any stand or clamping device that may damage
the tool.
GENERAL USE
• Stay alert and use common sense - do not use the sander when you are
tired or under the influence of alcohol, drugs or medication.
• Always wear eye protection when using the sander - eye protection must
provide protection from the front and the side.
• Always wear a dust mask when sanding dusty materials.
• Always wear ear protectors when using the sander.
• Do not over-reach - Keep proper footing and balance at all times.
• Never use any type of bottled gas as a source of power for the sander.
• Do not connect the air supply hose with your finger on the trigger of the
sander.
• Do not exceed the maximum pressure for the sander: 90 psi / 6.2 bar.
• Check hoses for leaks or worn condition before use and ensure that all
connections are secure.
• Do not use the sander for any other purpose than that described in this
booklet.
• Do not carry out any alterations or modifications to the sander.
• The sander should be serviced as required by your CLARKE dealer.
• Never use the sander if it is defective or operating abnormally.
• ALWAYS ensure the workpiece is firmly secured leaving both hands free to
control the sander.
• ALWAYS ensure the sander has stopped before putting it down after use.
• ALWAYS ensure that any attachments are correctly fastened before
connecting the sander to the power supply.

5
• Always disconnect from the air supply when:
a) Performing any maintenance.
b) The sander is not in use.
c) The sander will be left unattended.
d) Moving to another work area.
• Avoid damaging the sander for example, by applying excessive force.
• ALWAYS maintain the sander with care. Keep it clean for best and safest
performance.
• Quick change air-line couplings should not be located at the tool. They
add weight and could fail due to vibration.
• DO NOT force or misuse the sander. It will do a better and safer job at the
rate for which it was designed.
• This sander vibrates during use. Vibration may be harmful to your hands or
arms. Stop using the tool if discomfort, a tingling feeling or pain occurs and
seek medical advice before resuming use. Refer to Vibration Emissions on
page 13.
TRANSPORTATION
• Never carry the sander by the air supply hose.
• Never carry the sander with your finger on the trigger.
STORAGE
• When not in use the sander must be disconnected from the air supply and
stored in a dry place out of the reach of children (preferably in a locked
cabinet).
• Avoid storing the sander in environments where the temperature falls
below 0oC.

6
AIR SUPPLY REQUIREMENTS
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE THOROUGHLY FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE
USE OF COMPRESSORS AND COMPRESSED AIR SUPPLY.
• Air compressors used with the sander must comply with the appropriate
European Community safety directives.
• Use only clean, dry, regulated compressed air as a power source for the
sander.
• A build up of moisture in the air compressor will accelerate wear and
corrosion in the sander. 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), line presure may
need to be increased.
A typical airline
arrangement is
shown on the right.
If an automatic in-
line filter/regulator/
lubricator unit is
used it will keep the
tool in good
condition but should
be regularly
checked and
topped up with oil.
IMPORTANT: If a filter/lubricator unit is not used, the sander should be
lubricated with 2 to 6 drops of oil, at least once a day or after 2 hours work,
depending upon the working environment. The oil can be inserted through
the airline connection point.
AIRLINE SAFETY
• Never exceed the maximum operating pressure for the sander. A pressure
of 90 psi with a flow of 6 cfm is required. Too high an air pressure will
shorten the life of the tool due to excessive wear.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.

7
OVERVIEW
The CAT111 Orbital Sander is ideal for use in the automotive industry or any
task of smoothing wood, fibreglass or body filler. The sander features a
balanced ball-bearing design, rear exhaust & automatic throttle release. The
CAT111 sander holds standard 93 x 232mm sanding sheets which are
available from your CLARKE dealer.
Unpack and lay out the components, checking against the following list. Any
damage or deficiency should be reported to your CLARKE dealer
immediately.
• Orbital Sander
• Male screw-in adaptor
• Bottle of Airline Oil
• Operators Manual (this document)
ASSEMBLY
1. Remove the plastic blanking plug from the connection port of the sander .
2. 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.
3. Connect a suitable hose to
the sander as shown. Use the
screw-in adaptor supplied if
required.
4. Connect the other end of the
hose to the compressor.
(A whip hose with a quick
fit coupling is available
from your CLARKE dealer).
5. Turn on the air supply and
check for air leaks. Rectify
any found before proceding.
Your sander is now ready for
use.

8
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the compressor has been shut
down and the compressed air released from the air line.
2. Once the pressure has been released, disconnect the airline hose from
the sander.
STORAGE
1. Store the sander safely in its box in a dry, secure environment.
2. If the sander is not to be used for longer than 24 hours, run a few drops of
CLARKE airline oil into the air inlet and run the tool for a few seconds to
ensure that the oil has been well distributed throughout the sander.
3. When storing, ensure the blanking plug is replaced at the airline
connection port once the airline has been disconnected.
OPERATING INSTRUCTIONS
IMPORTANT: Only use sanding sheets designed for use with a rectangular
orbital sander;-pre-cut sheets (93 x 232mm) are available from your
CLARKE dealer.
1 Attach a sanding sheet to the
base of the sander using the
spring-loaded clips at each end
of the base as in Fig 1.
• Ensure the sanding sheet is
correctly aligned with the sander
and pulled tight enough to avoid
any creasing.
2. Place the sander on the
workpiece and press down on
the trigger to start the sander.
3. Adjust the operating speed if
required, by twisting the air
regulator as in Fig 2.
4. Release pressure from the trigger
to stop the sander.
5. Always ensure the sander has
stopped before putting it down.
Fig 1
Fig 2

9
TROUBLESHOOTING
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In the event that any of the above situations occurs, requiring the dismantling
and overhaul of the tool, contact your CLARKE International Service
Department on 020-8988-7400.

10
MAINTENANCE
WARNING! Make sure that the sander is disconnected from the air supply
before starting any cleaning or
maintenance procedures.
DAILY
• Drain water from the compressor air
tank and air-line.
• Pour a few drops of CLARKE air line
oil**, into the air inlet. This should be
carried out regardless of whether or
not an air line lubricator is used. If an
air-line lubricator is not used, this
procedure should be repeated after
every two to three hours of use.
WEEKLY
• Check the air inlet screen filter in Fig 3
and clean if necessary.
CLEANING
• Keep the body of the sander clean and free from debris. Grit or gum
deposits in the tool may reduce efficiency.
• After extensive use, remove the screen filter and flush out the sander with
gum solvent oil or an equal mixture of SAE No10 oil and paraffin. Allow to
dry before use.
SERVICING AND REPAIRS
• Major servicing and repair must be carried out by your local CLARKE
dealer.
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 line, or the use of connectors of improper size or
poor condition which will reduce air supply.
**Clarke Air Line Oil is available from your CLARKE dealer part no. 3050825.
ACCESSORIES
A wide range of airline accessories are available including filter/regulators,
lubricators, high pressure hoses, etc. Contact your CLARKE dealer for further
information, or call CLARKE International on 01992 565333.
Air Inlet Screen
Filter (located
here)
Fig 3

11
PARTS DIAGRAM

12
PARTS LIST
oN noitpircseD oNtraP oN noitpircseD oNtraP
1gnisuoH10111TACNOR42niPrednilyC42111TACNOR
2wercS20111TACNOR52gniR-O52111TACNOR
3rebbuR30111TACNOR62rotoR62111T
ACNOR
4raBgnisuoH40111TACNOR72edalBrotoR72111TACNOR
5reggirT50111TACNOR82eldnipS82111TACNOR
6niPreggirT60111TACNOR92ye
KffurdooW92111TACNOR
7rotalugeRriA70111TACNOR03teksaGraeR03111TACNOR
8gniR-O80111TACNOR13esaB13111TACNOR
9gniRreniat
eR90111TACNOR23rehsaWgnirpS23111TACNOR
01gniR-O01111TACNOR33wercSdaehssorC33111TACNOR
11telnIriA11111TACNOR43geLelbi
xelF43111TACNOR
21gniR-O21111TACNOR53wercS53111TACNOR
31metSevlaV31111TACNOR63wercS63111TACNOR
41gniR-O41111TACNOR73maC
cirtneccE73111TACNOR
51gnirpS51111TACNOR83wercS83111TACNOR
61gniR-O61111TACNOR93gnisuoHgniraeB93111TACNOR
71gulPevla
V71111TACNOR04teksaGgniraeB04111TACNOR
81revoCrelffuM81111TACNOR14rehsaW14111TACNOR
91gniRreniateR91111TACNOR24wercS
gniraeB24111TACNOR
02rehsaW02111TACNOR34pmalCrepaP34111TACNOR
12gniraeBdnEraeR12111TACNOR44noitceSesaB44111TACNOR
2
2etalPdnEraeR22111TACNOR54wercS54111TACNOR
32rednilyC32111TACNOR64daPgnidnaS64111TACNOR

13
VIBRATION EMISSIONS
MODEL No: CAT111
DESCRIPTION: AIR ORBITAL SANDER
Declared vibration emission value in accordance
with EN12096
Measured vibration emission value - a: less than
2.5m/s2
Values determined according to EN28622-1
Employers are advised to refer to the HSE publication “Guide for Employers”.
All hand held power tools vibrate to some extent, and this vibration is
transmitted to the operator via the handle, or hand used to steady the tool.
Vibration from about 2 to 1500 herz is potentially damaging and is most
hazardous in the range from about 5 to 20 herz.
Operators who are regularly exposed to vibration may suffer from Hand Arm
Vibration Syndrome (HAVS), which includes ‘dead hand’, ‘dead finger’, and
‘white finger’. These are painful conditions and are widespread in industries
where vibrating tools are used.
The health risk depends upon the vibration level and the length of time of
exposure to it……in effect, a daily vibration dose.
Tools are tested using specialised equipment, to approximate the vibration
level generated under normal, acceptable operating conditions for the tool
in question. For example, a grinder used at 45° on mild steel plate, or a
sander on softwood in a horizontal plane etc.
These tests produce a value ‘a
’ , expressed in metres per second per second,
which represents the average vibration level of all tests taken, in three axes
where necessary, and a second figure ‘K’, which represents the uncertainty
factor, i.e. a value in excess of ‘a’, to which the tool could vibrate under
normal conditions. These values appear in the specification panel below.
HAND-ARM VIBRATION

14
You will note that a third value is given in the specification - the highest
measured reading in a single plane. This is the maximum level of vibration
measured during testing in one of the axes, and this should also be taken into
account when making a risk assessment.
‘
a ’ values in excess of 2.5 m/s2are considered hazardous when used for
prolonged periods. A tool with a vibration value of 2.8 m/s2may be used for
up to 8 hours (cumulative) per day, whereas a tool with a value of 11.2 m/s2
may be used for ½ hour per day only.
The graph below shows the vibration value against the maximum time the
respective tool may be used, per day.
The uncertainty factor should also be taken into account when assessing a
risk. The two figures ‘ a ’ and ‘ K ’may be added together and the resultant
value used to assess the risk.
It should be noted that if a tool is used under abnormal, or unusual conditions,
then the vibration level could possibly increase significantly. Users must always
take this into account and make their own risk assessment, using the graph
above as a reference.
Some tools with a high vibration value, such as impact wrenches, are
generally used for a few seconds at a time, therefore the cumulative time
may only be in the order of a few minutes per day. Nevertheless, the
cumulative effect, particularly when added to that of other hand held power
tools that may be used, must always be taken into account when the total
daily dose rate is determined.

15
DECLARATION OF CONFORMITY