Clarke CAT80 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS GC06/13
6” DUAL-ACTION SANDER
MODEL NO: CAT80
Part No: 3110800

2
Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
INTRODUCTION
Thank you for purchasing this CLARKE product.
Before attempting to use the product, it is essential that you read this manual
thoroughly and carefully follow all instructions given. In doing so you will
ensure the safety of yourself and that of others around you, and you can also
look forward to the product 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 its intended 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.
ENVIRONMENTAL PROTECTION
Do not dispose of this product with general household waste. All tools,
accessories and packaging should be sorted, taken to a re-cycling
centre and disposed of appropriately.

3
Parts & Service: 020 8988 7400/E-mail: Part[email protected] or [email protected]
TABLE OF CONTENTS
INTRODUCTION .......................................................................... 2
GUARANTEE ................................................................................ 2
ENVIRONMENTAL PROTECTION ................................................. 2
TABLE OF CONTENTS ................................................................... 3
SAFETY PRECAUTIONS ................................................................ 4
OVERVIEW ................................................................................... 6
AIR SUPPLY REQUIREMENTS........................... ............................. 7
ASSEMBLY .................................................................................... 8
OPERATION...................................................................................9
TROUBLESHOOTING....................................................................10
MAINTENANCE .......................................................................... 11
PARTS LIST & DIAGRAM...............................................................12
SPECIFICATIONS .................................................................... ... 14
DECLARATION OF CONFORMITY ....................................... ..... 15

4
Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
SAFETY PRECAUTIONS
CAUTION: FAILURE TO FOLLOW THESE PRESCAUTIONS COULD RESULT IN
PERSONNAL INJURY, AND /OR DAMAGE TO PROPERTY
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.
Make sure that any other persons in the work area are dressed suitably
and are wearing eye and ear protectors.
4. Do not operate an abrasive tool where there are flammable vapours.
5. Keep the air supply hose away from heat, oil and sharp edges.
6. Do not fit the tool to any stand or clamping device that may damage the
tool.
GENERAL USE
1. Stay alert and use common sense - do not use the tool when you are tired
or under the influence of alcohol, drugs or medication.
2. Always wear eye protection when using the tool - eye protection must
provide protection from the front and the side.
3. Always wear ear protectors when using the tool.
4. Do not over-reach - keep proper footing and balance at all times.
5 Never use 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 of the
tool.
7. Do not exceed the maximum pressure for the tool: 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
booklet.
10. Do not carry out any alterations or modifications to the tool.
11. Always disconnect from the air supply when:
• Performing any maintenance.
• The tool is not in use.

5
Parts & Service: 020 8988 7400/E-mail: Part[email protected] or [email protected]
• The tool will be left unattended.
• Moving to another work area.
12 Never use the tool if it is defective or operating abnormally.
13. The tool should be serviced as required by your CLARKE dealer.
14. Avoid damaging the tool for example by applying excessive force.
15. ALWAYS maintain the tool with care. Keep it clean for best and safest
performance.
16. ALWAYS ensure the workpiece is firmly secured leaving both hands free to
control the tool.
17. ALWAYS ensure the tool has stopped before putting it down after use.
18. ALWAYS ensure that any attachments are correctly fastened before
connecting the tool to the power supply.
19. Quick change air-line couplings should not be located at the tool. They
add weight and could fail due to vibration.
20. DO NOT force or misuse the tool. It will do a better and safer job operating
at the rate for which it was designed.
21. Do not remove any labels. damaged labels should be replaced.
22. This tool 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.
TRANSPORTATION
1. Never carry the tool by the air supply hose.
2. Never carry the tool with your finger on the trigger.
STORAGE
1. 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).
2. Avoid storage in environments where the temperature is below 0oC.

6
Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
OVERVIEW
The CAT80 Sander is ideal for use in garages and workshops. Random orbit
sanders give a virtually scratch - free finish on various surfaces prior to
painting or varnishing the finished surface.
Unpack your sander should include the following items. Any damage or
deficiency should be reported to your CLARKE dealer immediately.
• Heavy Duty Dual Action Sander
• 6” Sanding Pad
• Operating Instructions (this document)
Your dual -acting sander 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.
THROTTLE
AIR INLET
REGULATOR VALVE
LOCKING NUT

7
Parts & Service: 020 8988 7400/E-mail: Part[email protected] or [email protected]
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.
• 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 in the air compressor will accelerate wear and
corrosion in the moving parts. 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.
• Never exceed the maximum operating pressure for the tool.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.
• A pressure of 90psi with a flow of 6 cfm is required. Too high an air pressure
will shorten the life of the tool due to excessive wear.
A typical airline layout is shown. 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 air tool 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 fitting.

8
Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
BEFORE USE
INSTALLING THE DISC
1. To assemble the pad to the tool,
turn the locking nut (A) until the
knurled portion contacts the flat
surface on the output spindle (B).
2. Thread the pad into the spindle
by gripping theorbital hub (C)
with one hand and the pad with
the other.
3. Turn the locking nut until the
spindle turns freely. Do Not
operate the tool with the spindle
in the locked mode as performance would be severly affected and a
hazardous situation could result.
CONNECTING THE AIR SUPPLY
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLIES.
Note: Ensure the compressor is turned off.
1. Remove the plastic blanking plug
from the connection port of the
tool as shown.
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
tool as shown.
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. The tool is now ready for use.
A
B
C

9
Parts & Service: 020 8988 7400/E-mail: Part[email protected] or [email protected]
OPERATION
IMPORTANT: Only use abrasive sanding pads designed for use with this type of
150mm dia sanding pad.
1. 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.
2. Rest the sander on the workpiece
and start the machine. Let the
sander 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.
4. 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.
5. Release the trigger to stop the tool.
6. 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 pressure released.
2. Once the pressure has been released, disconnect the air supply hose from
the tool.
STORAGE
1. Store the tool safely in its box in a dry, secure environment.
2. If the tool 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 tool.
3. When storing, ensure the blanking plug is replaced on the airline
connector once the airline has been disconnected.
Regulator

10
Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
MOTPMYS MELBORP NOITULOS
snurlooTlamronta
nwodswolstubdeeps
rednudaol.
.nrowstraprotoM.1
gnikcitsronroW.2
kcaloteudmsinahcem
.t
nacirbulfo
rofrelaedotnruteR.1
luahrevo
liognitacirbullootriapirD.2
kaosdnatelniriaotni
.strapgnivom
riA.yl
wolssnurlooT
morfylthgilswolf
.tsuahxe
demmajstraprotoM.1
tridro/&mughtiw
.selcitrap
desolcnirotalugeR.2
.no
itisop
wolfrialareneG.3
.tridybdekcolb
rofretlifriatelnienimaxE.1
.ssenilnaelc
nepootrotalugertsujdA.2
.noi
tisop
trohsnilootetarepO.3
esrever/drawroffostsrub
.noitator
riA.nurtonlliwlooT
morfyleerfswolf
.tsuahxe
eud
kcutssenavrotoM.1
ngieroffopudliubot
.laretam
&ylppusriatcennocsiD.1
ylbmessalootetator
.yllaunam
trohsnilo
otgnitarepoyrT.2
esrever/drawroffostsrub
.noitator
.3yltneggnisuohrotompaT
.tellamrebburhtiw
riafospordwefa
pirD.4
ehtotniliognitacirbulloot
gnivomkaosottelniria
.strap
.ffotuhstonlliwlooTsgnir-OelttorhT.1
ddetaeston
rodegama
..yltcerroc
nruterrognir-OecalpeR.1
.riaperrofrelaedekralCot
TROUBLESHOOTING
ACCESSORIES
A wide range of 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.

11
Parts & Service: 020 8988 7400/E-mail: Part[email protected] or [email protected]
MAINTENANCE
WARNING! MAKE SURE THAT THE TOOL 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 a lubricator is
not used, this procedure should
be repeated after every two to
three hours of use.
WEEKLY
• Check the air inlet screen filter shown in Fig 4 and clean if necessary.
CLEANING
• Keep the body of the tool clean and free from debris. Grit or gum deposits
in the tool may reduce efficiency.
• After extensive use, remove the inlet screen filter and flush out the
mechanism with gum solvent oil or an equal mixture of SAE No10 oil and
paraffin. Allow to dry before use.
SERVICE AND REPAIR
• Any major servicing and repairs should be carried out by your local
CLARKE dealer or 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 line, or the use of connectors of improper size or
poor condition which will reduce air supply.
**Clarke Airline Oil is available from your CLARKE dealer: part no. 3050825.
Air Inlet Screen
Filter (located
here)

12
Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
PARTS LIST AND PARTS DIAGRAM

13
Parts & Service: 020 8988 7400/E-mail: Part[email protected] or [email protected]
oN noitpircseD oN noitpircseD
1daPgnidnaS12llaBleetS
2tuNecnalaBwercS22etalPdnE
3tuNecnalaBrehsaW32wercSpaC
4tuNecnalaB42gniraeBllaB
5rec
apSthgiewretnuoC52wercS
6rehsaWevaW62pilcriC
7tuNxeH72relffuM
8tfahScirtneccE82revoCrotoM
9gniraeBllaB92paCevlaV
01ydoBci
rtneccE03gnirpS
11wercSkcoL13metSevlaV
21eldnaHrotoM23gniR"O"
31 etalPdnE33pilcriC
41 tfahSrotoM43sgniR-OhtiwrotalugeRr
iA
51 yeKffurdooW53reveLelttorT
61 wercSpaC63niPreveLelttorhT
71 gniraeBllaB73rotcennoCesoH
81 rotoR83pirGeldnaH
91 eda
lBrotoR93a/n
02 rednilyC04pilcriC
PARTS LIST AND PARTS DIAGRAM
ABRASIVE DISCS
Replacement abrasive discs (self adhesive - 6” (150mm) dia) are available
from your CLARKE dealer:
Fine Part no. 6502097
Medium Part no. 6500809
Coarse Part no. 6502102

14
Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]
erutaeF noitacificepS
rebmuNledoM08TAC
noitpmusnoCriAlanimoNmfc6
erusserPriAgnitarepO)rab2.6(isp09
eziStelnIriAPSB"4/
1
deepSmumixaMmpr000,01
eziSesoHmuminiM)mm8("61/5
L(leveLerusserPdnuoS
AP
)Bd08
)bDawL(leveLrewoPdnuoS39
sleveLnoitarbiVs/m1.8
2
eziSdaPaidmm051
thgieWgk6.1
SPECIFICATIONS

15
Parts & Service: 020 8988 7400/E-mail: Part[email protected] or [email protected]
DECLARATION OF CONFORMITY