Clarke X-PRO CAT 160 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0217
PA L M S A N D E R
MODEL NO: CAT160
PART NO: 3120174

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INTRODUCTION
Thank you for purchasing this CLARKE Palm 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.
SPECIFICATION
Please keep these instructions in a safe place for future reference.
Model Numbers CAT160
Operating Pressure 90 psi (6.2 bar)
Air Consumption @ 6.3 bar 4.5 cfm (2.1L/sec) rated average
14.8 cfm (7.0L/sec) maximum
Air Inlet Size 1/4” BSP female thread
Vibration Level 8.5 m/s2
Uncertainty Factor (K) 1.5
Sound Power Level 98 dB LWA
Sound Pressure Level 87 dBA
Uncertainty Factor (K) 3.0
Dimensions (L x D x H) 220 x 150 x 110 mm (with backing pad
200 x 105 x 98 mm (without backing pad)
Weight 1.1 kg
Max Speed 10,000 rpm
Speed Control Variable
Dust extract hose 1335 long x 21 dia
Sanding pad Hook & Loop 150 mm dia
Thread type M8 x 24TPI

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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.
USE OF AIR POWERED TOOLS
1. Stay alert and use common sense - do not operate this tool when you are
tired or under the influence of alcohol, drugs or medication.
2. Always wear eye protectors when using air tools. Eye protectors must
provide protection from flying particles from the front and the side.
3. Do not overreach - keep proper footing and balance at all times.
4. Never use oxygen, CO2, combustible gasses, or any bottled gas, as a
source of power for an air tool. This product should only be used with a
suitably rated compressed air supply.
5. Do not connect the air hose with your finger on the trigger of the tool.
6. Do not fit the air tool to any stand or clamping device that may damage it.
7. Do not exceed the maximum pressure for the tool.
8. Keep the air hose away from heat, oil and sharp edges.
9. Check hoses for leaks or excessive wear before use, and ensure that all
connections are secure.
10. Do not use the tool for any other purpose than described in this manual.
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.
13. Never use the tool if it is defective or operating abnormally.
CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN
PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

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14. This air tool should be serviced at regular intervals by qualified service
personnel.
15. Avoid damaging the air tool by applying excessive force of any kind.
16. Always maintain the air tool with care. Keep it clean for the best and safest
performance.
17. ALWAYS ensure the workpiece is firmly secured leaving both hands free to
control the tool.
18. ALWAYS ensure the tool has stopped before putting it down after use.
19. ALWAYS ensure that any attachments are correctly fastened before
connecting the tool to the power supply
20. Do not force or misuse the air tool. It will do a better and safer job at the
rate for which it was designed.
21. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
22. Do not remove any labels. Damaged labels should be replaced.
23. 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. Inspect the sanding pad before use. Do not use if cracked or broken.
Check that the rated speed of the backing pad is at least as high as that
of the machine.
2. Avoid contact with the moving sanding pad and wear suitable gloves to
protect the hands.
3. Never start the tool unless the abrasive pad is applied to the workpiece.
4. Beware of potentially explosive atmospheres being caused by dust / fumes
resulting from sanding and use dust extraction systems where possible.
5. 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.
DUST EXTRACTION
The sander is provided with a dust extraction facility. Please note however,
that this does not preclude the user from wearing a face mask to prevent the
inhalation of dust particles.

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It is an EEC requirement that a dust extraction facility be provided on power
tools, however, due to the nature of the tool, some of the dust produced will
be forced into the surrounding atmosphere and will not be collected.
TRANSPORTATION
1. Never carry the tool by the air hose or with your finger on the trigger.
2. 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.
IMPORTANT
Please read all of the safety and operating instructions carefully before using
this product. The following safety symbols are to be found on the machine.
Read this instruction
booklet carefully
before use.
Wear ear protection.
Wear eye protection. Wear dust mask.

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OVERVIEW
The CAT160 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.
Your sander should include the items above. Any damage or deficiency
should be reported to your CLARKE dealer immediately.
NO DESCRIPTION NO DESCRIPTION
1 Dust collection tube 6 Speed Control Regulator
2 Sanding Pad 7 Spanner
3 Trigger 8 1/4” BSP male connector
4 Waste Outlet 9 Dust Bag
5 1/4” BSP Air Inlet Connection

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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 & topped up with oil. Clarke air-line oil should be
used, and the lubricator adjusted to approx 2 drops per minute.
• Never exceed the maximum operating pressure for the tool. 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 A COMPRESSED AIR SUPPLY.

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BEFORE USE
FITTING A SANDING DISC
1. Select the disc to be used which
MUST be 150mm diameter with
hook and loop backing.
2. Line up the holes in the disc with
those on the sanding pad. (This is
necessary for dust extraction
purposes). Press the disc firmly onto
the pad to secure it.
CONNECTING THE AIR SUPPLY
Ensure the compressor is turned off and that the trigger is NOT depressed when
connecting the air line to avoid inadvertent starting of the sander.
1. Remove the protective plug from
the air inlet and connect a suitable
hose with a male end fitting or use
the adaptor supplied to connect a
suitable hose.
2. Connect the other end of the hose
to the compressed air supply.
3. Turn on the air supply and check
for air leaks. Rectify any found
before proceeding.
• PTFE tape may be useful for sealing threaded connections.
4. If required, connect an in-line mini oiler to the tool. A mini oiler helps to
prolong the life of the air tool.
5. 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.
6. A gauze filter is fitted within the air inlet. Ensure this filter is always kept
clean. An airline can be connected to the adapter, via a quick release
coupling (not supplied).
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR
COMPRESSORS AND A COMPRESSED AIR SUPPLY.

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CONNECTING THE DUST COLLECTION TUBE & BAG
1. Push the dust collection tube onto
the waste outlet.
2. Use the string to tie the dust
collecting bag onto the smaller
end of the tube.
3. The dust bag should be emptied
regularly:- do not wait until it is
completely full. Gently pull open
the velcro flap across the end of
the bag to empty the contents
into your bin.
Your sander is now ready for use. Alternatively, vacuum extract can be used.
OPERATION
IMPORTANT: Only use abrasive sanding pads designed for use with this type
of 150mm dia sanding pad (rated at over 10000rpm).
1. Squeeze the trigger against the
body of the tool to start.
• Use the speed regulator to set
the speed.
• Move the regulator lever
forwards for maximum speed
and back to slow down.
2. Rest the sander on the workpiece
before starting it. Let the sander 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.
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 sander.
5. Always ensure the sander 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. Squeeze the trigger to discharge any compressed air from the sander and
air hose.
3. Once the pressure has been released, disconnect the air supply hose from
the sander.
MAINTENANCE
Please note that factors other than the tools condition 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.
DAILY
1. Before use, drain water from the air-line and compressor.
2. Lubricate the air tool daily for optimum performance, using a high quality
airline oil either via a lubricator in the air supply system or by placing a few
drops into the air inlet immediately before use. This should be carried out
regardless of whether or not an in-line lubricator is used.
CLEANING
1. Keep the sander clean and free from debris.
2. Grit or gum deposits in the mechanism may eventually reduce efficiency.
This condition can be corrected by cleaning the air inlet filter and flushing
out the tool with gum solvent oil or an equal mixture of SAE No10 oil and
paraffin.
3. Failing this, the tool should be disassembled, thoroughly cleaned, dried
and reassembled. You may prefer to take the tool to your CLARKE dealer if
internal maintenance is required.
4. If the sander becomes sluggish and the air supply is of good quality, it may
be necessary to replace worn or damaged parts. You may prefer to take
the tool to your Clarke dealer if internal maintenance is required.
WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

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5. If the surface of the sanding pad
becomes damaged and unable
to grip the disc, so requiring
replacement, or if the sander
needs to be dismantled, a spanner
is supplied to unlock the sanding
pad from the sander. Engage it
with the drive nut after lifting up
the rubber skirt and twist off the
sanding pad.
TROUBLESHOOTING
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 tool to your local Clarke dealer.
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Piston parts worn.
2. Worn or sticking
mechanism due to
lack of lubricant.
1. Return to Clarke dealer
for repair.
2. Drip lubricating oil into the
air inlet. Allow oil to soak
moving parts before using
Tool runs slowly. Air flows
weakly from exhaust.
1. Moving 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 short
bursts.
Tool will not run. Air
flows freely from
exhaust.
1. Piston 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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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 depress the trigger in order to lubricate
the internal parts.
When not in use, the sander should be disconnected from the air supply and
stored in a dry place out of the reach of children. Avoid storing in a damp
environment.
ABRASIVE DISCS
Replacement hook and eye backed abrasive discs (6”/150mm) diameter are
available from your CLARKE dealer:
ACCESSORIES AND CONSUMABLES
A wide range of airline accessories is available including filter/regulators,
lubricators, high-pressure hoses (5 to 50 metres) etc. Contact your Clarke
dealer or Clarke International Service Department for further information.
Clarke Air-lne Oil (Part no. 3050825) is available from your Clarke dealer.
ENVIRONMENTAL PROTECTION
Do not dispose of redundant or damaged airline components with general
household waste. All tools, accessories and packaging should be sorted,
taken to a re-cycling centre and disposed of appropriately.
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.
Fine Part No 6463305
Medium Part No 6463310
Coarse Part No 6463315

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DECLARATION OF CONFORMITY

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PARTS LIST
No Description No Description
1 Main Housing 23 Sanding Pad
2HeadCover 24Trigger
3 Washer 25 Trigger Hinge Pin
4 Bearing 26 Trigger Valve
5 Bolt 27 O-Ring
6 Rear Plate 28 Cushion
7 Rotor 29 Nut
8 Rotor Blade 30 O-Ring
9 Cylinder 31 Plunger
10 Front Plate 32 Dust Tube Connector
11 Bearing 33 O-Ring
12 O-Ring 34 Muffler
13 Mounting Ring 35 Dust Connector item 1
14 Spindle 36 Dust Connector item 2
15 Woodruff Key 37 Lubricating Ring
16 Screw 38 Tilting Valve
17 Bearing 39 Spring
18 Fibre Ring 40 Air Inlet Connector
19 Washer 41 Dust Collecting Tube
20 Circlip 42 Dust Collecting Bag
21 Bearing Support 43 Wrench
22 Dust Cover

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PARTS DIAGRAM