Clarke X-Pro CAT168 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0417
RIGHT ANGLE SANDER
MODEL NO: CAT168
PART NO: 3120182

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INTRODUCTION
Thank you for purchasing this CLARKE Right Angle 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.
Please keep these instruction in a safe place for future reference.
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 CAT168
Part Number 3120182
Min. Hose Size (ID) 8 mm (5/16”)
Operating Pressure 90 psi (6.2 bar)
Air Consumption 13 cfm (max load), - 4cfm nominal
Air Inlet Size 1/4“ BSP Female
Sound Pressure Level (LpA dB) 85.8 dB(A)
Sound Power Level (LwA dB) 96.8 dB(A)
Vibration Levels 5.897 m/s2
Vibration Uncertainty K 1.5
Weight 0.7 kg
Speed Settings
1 6,500 (+/- 10%)
2 9,500 (+/- 10%)
3 12,500 (+/- 10%)
4 15,000 (+/- 10%)

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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 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.
6. Do not fit the sander to any stand or clamping device that may damage it.
7. Do not exceed the maximum pressure for the tool of 7 bar.
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 sander 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 sander 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.
13. Never use the sander if it is defective or operating abnormally.
14. Avoid damaging the sander by applying excessive force of any kind.
15. Always maintain the sander with care. Keep it clean for the best and safest
performance.
16. ALWAYS ensure the workpiece is firmly secured.
17. ALWAYS ensure the sander has stopped before putting it down after use.
18. ALWAYS ensure that any attachments are correctly fastened before
connecting the sander to the air supply.
19. Do not force or misuse the sander. It will do a better and safer job at the
rate for which it was designed.
20. Quick change couplings should not be located at the air tool. They add
weight and could fail due to vibration.
21. 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 if possible, 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 sander 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.
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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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 air 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.
• 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 6.2 bar
(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.
PRODUCT OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Sanding Pad 5 Air Exhaust Outlet/deflector
2 Drive Locking Tool 6 Speed Adjuster
3 Safety Trigger 7 Grease Nipple
4 Female air inlet

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BEFORE USE
FITTING/REMOVING THE SANDING PAD
1. Rotate the eccentric wheel by
hand until the locking hole can be
seen through the slot in the front
housing.
2. Insert the drive locking tool into the
hole to stop the drive from
rotating.
3. Hold the drive locking tool firmly
while screwing on the sanding pad
clockwise. Make sure the sanding
pad is tight and secure.
4. The pad can be removed by unscrewing anticlockwise.
FITTING/REMOVING THE SANDING DISC
1. Fit the backing disc to the sander
by locking the moving drive
spindle with the key supplied and
screwing the disc tightly into
place.
2. Select the disc to be used which
MUST be correct disc with hook
and loop backing.
3. Press the disc firmly onto the pad
to secure it.
CONNECTING THE AIR SUPPLY
1. Connect one end of the hose to the compressed air supply.
2. Remove the protective plug from the air inlet and connect a suitable hose
as shown.
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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3. Turn on the compressed 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 sander. A mini oiler
helps to prolong the life of the tool.
5. If a mini-oiler is not being used, run
a few drops of oil through the
sander 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 inside 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 air line.
• Your sander is now ready for use
• You can fit a whip hose with a quick fit coupling if required
(available from your Clarke dealer.)
OPERATION
IMPORTANT: Only use abrasive sanding pads designed for use with this type
of sanding pad.
1. To start, squeeze the trigger
against the body of the sander.
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.

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4. Release the trigger to stop the
sander.
5. Set the speed by twisting the
adjustable 4-speed regulator. The
embossed number should line up
with the mark on the air inlet to
show the speed.
• Speeds are stated in the
specification on page 2.
6. Always ensure the sander has
stopped before putting it down.
SETTING THE EXHAUST DEFLECTOR
The direction of the exhaust air
leaving the tool can be adjusted by
rotating the exhaust deflector.
1. Twist the exhaust deflector sleeve
to direct the air as required to
deflect air away from the
workpiece or operator
DISCONNECTING THE AIR SUPPLY
1. Do not disconnect the compressed air supply hose until the air supply has
been shut down or isolated at the shut off valve and the compressed air
expelled by running the tool until it stops.
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.

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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 OR EVERY USE
1. Before use, drain water from the air-line and compressor.
2. Lubricate the sander daily or before each use 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.
3. Keep the sander clean and free from debris.
CLEANING & OVERHAULING
1. The right angle drive is fitted with a
grease nipple to provide a facility
for lubrication of the drive gears.
After extensive use, apply a shot
of general purpose grease using a
suitable grease gun.
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. Allow the mixture to soak
into the moving parts before
draining off the excess.
WARNING: MAKE SURE THAT THE SANDER IS DISCONNECTED FROM THE
AIR SUPPLY BEFORE STARTING ANY CLEANING, OR MAINTENANCE
PROCEDURES.

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3. Failing this, 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.
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 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.
ABRASIVE DISCS
Replacement hook and eye backed abrasive discs (2” (50mm) dia) are
available from your 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.
CAT173 60 grit Part No 3120190
CAT174 120 grit Part No 3120191
CAT175 180 grit Part No 3120192

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TROUBLESHOOTING
AIRLINE 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.
SYMPTOM PROBLEM SOLUTION
Tool runs at normal
speed but slows down
under any load.
1. Excessive pressure on
the 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 Main Housing 29 Cylinder
2 Trigger 30 Bushing
3 Lever Block 31 Front Plate
4 Spring 32 Steel Ball
5Bolt 33Bearing
6 Bolt 34 Major Gear
7 O-ring 35 Cushion
8 O-ring 36 Securing Ring
9 Valve Stem 37 Set Nut
10 Spring 38 Right Angle Casing
11 O-ring 39 Grease Nipple
12 Screw Nut 40 Bearing
13 Rubber Cover 41 Gear
14 Rear Cover 42 Bearing
15 O-ring 43 Spindle
16 Muffler 44 Woodruffe Key
17 O-ring 45 Fixing Ring
18 Air Regulator 46 Front Housing
19 O-ring 47 Set Screw
20 Air Inlet 48 Eccentric Drive Wheel
21 Pin Sleeve 49 Screw
22 Spring 50 Screw
23 Front Cover 51 Bearing Seat
24 Bearing 52 Bearing
25 Rear Plate 53 Circlip
26 Bolt 54 Sanding Pad
27 Rotor 55 Drive Locking Tool
28 Rotor Blade

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DECLARATION OF CONFORMITY