Clarke X-PRO CAT165 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0417 ISS1
10MM AIR BELT SANDER
MODEL NO: CAT165
PART NO: 3120179

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INTRODUCTION
Thank you for purchasing this CLARKE 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.
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.
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.
Read this instruction
booklet carefully
before use.
Wear ear protection
Wear eye protection Wear dust mask

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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.
USE OF AIR POWERED TOOLS
1. Stay alert and use common sense - do not operate the sander when you
are tired or under the influence of alcohol, drugs or medication.
2. Always wear eye protectors when using the sander- Eye protection must
provide protection from flying particles from the front and the side.
3. Always wear ear protectors when using the sander.
4. Do not overreach - Keep proper footing and balance at all times.
5. Never use any type of bottled gas as a source of power.
6. Do not connect the air supply hose with your finger on the trigger.
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. Keep the air supply hose away from heat, oil and sharp edges.
10. Do not use the tool for any other purpose than that described in this
manual.
11. Do not fit the tool to any stand or clamping device that may damage it.
12. Do not carry out any alterations or modifications to the sander.
13. Always disconnect from the air supply when:
• Performing any maintenance
• The tool is not in use.
• The sander 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 sander to another person.
14. Never use the tool if it is defective or operating abnormally.
15. The tool should be serviced if required, by qualified service personnel.
16. Avoid damaging the sander for example, by applying excessive force of
any kind.
17. ALWAYS maintain this tool with care. Keep it clean for the best and safest
performance.
18. Quick change couplings should not be located at the tool. They add
weight and could fail due to vibration.
19. Do not force or misuse the tool. It will do a better and safer job at the rate
for which it was designed.
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. Inspect the sanding belt before use. Do not use if frayed.
2. Avoid contact with the moving sanding belt and wear suitable gloves to
protect the hands.
3. Never run the sander unless the abrasive belt is applied to the workpiece.
4. Beware of potentially explosive atmospheres being caused by dust / fumes
resulting from sanding and used 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.
TRANSPORTATION
1. Never carry the sander by the air supply hose.
2. Never carry the sander with your finger on the trigger.

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OVERVIEW
When unpacking the tool, any damage or deficiency should be reported to
your CLARKE dealer immediately. The carton contains:
•Sander
• 60, 80 and 120 grit sanding belts
• Allen (hex) key
Your 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.
NO DESCRIPTION NO DESCRIPTION
1 Idler Pulley 5 Belt Release Catch
2 Drive Pulley 6 Airline Connector
3 Abrasive Belt 7 Angle Adjustment Screw
4 Throttle Lever 8 Allen Key

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THE COMPRESSED AIR SUPPLY
AIR SUPPLY 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 airline 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.
• The minimum hose diameter should be 5/16”(8mm) ID and fittings
should have the same internal dimensions.
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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• Never exceed the maximum operating pressure for the tool. It is
recommended that air pressure to this tool does not exceed 90 psi
(6.2 bar) 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.
BEFORE USE
INSTALLING THE BELT
1. To install or replace sanding belt,
push the arm/idler assembly
towards the body of the tool
against the resistance of the spring
until it latches.
2. The belt can now be removed and
refitted.
3. Ensure the belt is correctly tracking
on the rollers before pressing the
release catch to release the spring
loaded arm. This will re-tension the belt.
ADJUSTING THE ANGLE OF THE SANDER
1. To adjust the working angle of the
sander, slacken the hex headed
screw using the hex key supplied
and set the sander arm to the
required position, then secure by
re-tightening the hex screw.
• Only use sanding belts
designed for use with this type of
sander.

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CONNECTING THE AIRLINE
1. Remove the protective plug from
the air inlet port and connect a
suitable hose as shown.
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 airline 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 in place
and is kept clean. An airline is connected to the adapter, preferably via a
quick release coupling (not supplied).
7. Ensure the trigger is NOT depressed when connecting the airline.
• 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.)
OPERATION
OPERATING THE SANDER
1. Ensure your fingers are clear of the sanding belt.
2. To begin work, rest the belt on the workpiece and gently start the sander.
3. Squeeze the throttle lever against the body of the tool to start the sander.
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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• Let the tool 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 belt, reducing
efficiency and placing an additional burden on the motor.
4. Take care to keep the sander moving around at all times. Avoid dwelling in
one place for more than a moment.
5. When finished sanding, release the throttle lever and allow the motor to
stop before carefully putting the tool down.
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the air supply hose until the air supply 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 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 airline, or the use of connectors of
improper size or poor condition which will reduce the air supply.
DAILY
1. Before use, drain water from the airline and compressor.
2. Lubricate the air tool daily for optimum performance. Use 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 & OVERHAUL
1. Keep the moving parts clean and free from debris.
2. If the sander becomes sluggish and the air supply is of good quality, it may
be necessary to replace worn or damaged parts.
WARNING: MAKE SURE THAT THE SANDER IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE
PROCEDURES.

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3. 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.
4. 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.
STORAGE
If the tool is to be stored or is idle for longer than 24 hours, run a few drops of
Clarke airline oil into the air inlet and depress the trigger in order to lubricate
the internal parts.
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. Avoid storing in a damp
environment.
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 on 01992 565333.
Clarke Airline Oil (part no. 3050825) is available from your CLARKE dealer.
ABRASIVE BELTS
Replacement abrasive belts are available from your CLARKE dealer:
CAT166 - 1 x 60 grit /1 x 80 /1 x 120 grit
(pack of 3) - 10 x 330mm
Part no. 3120180

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TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
sander.
2. Motor parts worn.
3. Worn or sticking
mechanism due to
lack of lubricant.
1. Reduce the force
applied to the sander.
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. 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. O-rings damaged or
ill-fitting in seat.
1. Return to Clarke dealer
for repair.

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PARTS DIAGRAM

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PARTS LIST
No Description No Description
1 Sanding Belt 23 End Cap
2 Idler Pulley 24 Bearing 607zz
3 Washer 25 End Plate A
4 Idler Pulley Screw 26 Cylinder
5 Bracket 27 Rotor Blades (set of 5)
6 Tension Bar 28 Rotor
7 Setscrew 3x10 29 Throttle Lever
8 Countersunk machine screw 3 x 8 30 Lever Pin
9 Spring 31 Valve Body
10 Roll Pin 32 O-Ring
11 Spring 33 O-Ring
12 Shoe 34 O-Ring
13 Pan head machine screw 4x8 35 Valve Stem
14 Guard Body 36 O-Ring
15 Set Screw 5x15 37 Valve Spring
16 Hexagon Pulley 38 Air Deflector
17 Drive Pulley 39 Air Inlet
18 Housing 40 Release Catch
19 Bearing 628zz 41 Spring
20 End Plate B 42 Lever/Spring Pin
21 Spacer 43 Lever Hinge Roll Pin
22 Woodruffe Key

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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 Numbers CAT165
Part Number 3120179
Weight 0.8 kg
Min. Hose Size (ID) 8 mm (5/16”)
Air Inlet Size 1/4“BSP Female
Operating Pressure 90 psi (6.2 bar)
Air Consumption 18 cfm (max) - 6 cfm (rated)
Max No Load Speed 20000 rpm @ 90psi
Sound Pressure Level (LpA dB) 93 dB(A)
Sound Power Level (LwA dB) 104 dB(A)
Vibration Levels 4.8 m/s2
Vibration Uncertainty K 1.5

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DECLARATION OF CONFORMITY