Clayton 770-1231OS User manual

OPERATOR’S MANUAL FOR CLAYTON
LOW PROFILE 12,000 RPM 3 in. (77 mm)
ERGOLITE RANDOM ORBITAL SANDERS
Operator Instructions
Includes –Parts Page, Parts List, Please Read and Comply,
Proper Use of Tool, Work Stations, Putting the Tool Into Ser-
vice, Operating Instructions and Compressor Layout, Service
Tools and Accessories, Service Instructions, Back-Up Pads,
Declaration of Conformity
CLAYTON Associates, Inc. 1650 Oak Street Lakewood, NJ 08701 USA
declare on our sole responsibility that the products
Place and date of issue Name Signature or equivalent marking of authorized person
Important
Read these instructions care-
fully before installing, operating,
servicing or repairing this tool.
Keep these instructions in a safe
accessible location.
Manufacturer/Supplier Required Personal Safety Equipment
Recommended Airline
Size - Minimum
3/8 in 10 mm
Recommended Maximum
Hose Length
25 feet 8 meters
Air Pressure
Maximum Working Pressure 90 psig 6.2 bar
Recommended Minimum NA NA
Breathing Masks
Ear Protection
Safety Glasses
Safety Gloves
Lakewood, NJ 2019-04 James E. CLAYTON
CLAYTON Associates, Inc.
TEL [phone]
www.VacuumSanding.com
3 in. (77 mm) Ergolite Random Orbital Sanders (See Product “Specifications” Table for particular Model) to which this declaration
relates is in conformity with the following standard(s) or other normative document(s) EN ISO 15744:2008. Following the provisions
of 89/392/EEC as amended by 91/368/EEC, 93/44/EEC & 93/68/EEC Directives and consolidating Directive 2006/42/EC
1
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

OPERATOR’S MANUAL FOR CLAYTON
LOW PROFILE 12,000 RPM 3 in. (77 mm)
ERGOLITE RANDOM ORBITAL SANDERS
Warranty
Please Read and Comply with
Proper Use of Tool
This sander is designed for sanding all types of materials i.e. metals, wood, stone, plastics, etc. using abrasive designed for this purpose.
Do not use this sander for any other purpose than that specified without consulting the manufacturer or the manufacturer’s authorized
supplier.
Do not use back-up pads that have a working speed less than 12,000 RPM free speed. Never use back-up pads that have a weight
and/or size different than the machine was specifically designed for.
1) General Industry Safety & Health Regulations, Part 1910, OSHA 2206, available from: Superintendent of Documents; Government
Printing Office; Washington DC 20402
2) Safety Code for Portable Air Tools, ANSI B186.1 available from: American National Standards Institute, Inc.; 1430 Broadway; New
York, New York 10018
3) State and Local Regulations.
All CLAYTON Ergolite Random Orbital Sanders are warranted for defects in materials or workmanship for one year from the date of
delivery to the user. Combined with the CLAYTON name, this Warranty expresses our total confidence in the superior quality, durability,
and performance of the CLAYTON LP. To receive any expressed or implied warranty, tool must be repaired by an authorized CLAYTON
Service Center. The "Service Instructions" section in this document is provided for use after completion of the warranty period. To
receive warranty, tools must be operated under the conditions as described in the Putting the Tools into Service section of this docu-
ment and be connected to an air supply system as shown in Figure 1. Tools that have been exposed to extreme conditions will be
covered under war ranty at the sole discretion of CLAYTON.
2
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

1. General safety rules:
-“Read and understand the safety instructions before
installing, operating, repairing, maintaining, changing
accessories on, or working near the sander or polisher.
Failure to do so can result in serious bodily injury.”
-“Only qualified and trained operators should install, adjust
or use the sander or polisher.”
-“Do not modify this tool. Modifications can reduce the
effectiveness of safety measures and increase the risks to
the operator.”
-“Do not discard the safety instructions; give them to the
opratr.”
-“Do not use a sander or polisher if the tool has been
damaged.”
-“Tools shall be inspected periodically to verify that the
ratings and markings are legibly marked on the tool. The
employer/user shall contact the manufacturer to obtain
replacement marking labels when necessary.”
2. Projectile hazards
-“Be aware that failure of the workpiece or accessories, or
even of the inserted tool itself can generate high-velocity
projectiles.
-”Always wear impact-resistant eye protection during
operation of the sander or polisher. The grade of protection
required should be assessed for each use.”
-“For overhead work, wear a safety helmet.”
-“Ensure that the workpiece is securely fixed.”
3. Entanglement hazards
“Choking, scalping and/or lacerations can occur if loose
clothing, personal jewellery, neck wear, hair or gloves are
not kept away from the tool and its accessories.”
4. Operating hazards
-"Use of the tool can expose the operator's hands to
hazards, including cuts and abrasions and heat. Wear
suitable gloves to protect hands."
-"Operators and maintenance personnel shall be physically
able to handle the bulk, weight and power of the tool."
-"Hold the tool correctly; be ready to counteract normal or
sudden movements and have both hands available."
-"Maintain a balanced body position and secure footing."
-"Release the start-and-stop device in the case of an
interruption of the energy supply."
-"Use only lubricants recommended by the manufacturer."
-"Personal protective safety glasses shall be used; suitable
gloves and protective clothing are recommennded."
-"Inspect the backing pad before each use. Do not use if
cracked or broken or if it has been dropped."
-"Avoid direct contact with the moving sanding pad in order
to prevent pinching or cutting of hands or other body parts.
Wear suitable gloves to protect hands."
-"Never run the tool unless abrasive is applied to the
workpiece."
-"There is a risk of electrostatic discharge if used on plastic
and other non-conductive materials."
-"Potentially explosive atmospheres can be caused by dust
and fumes resulting from sanding or grinding.
Always use dust extraction or suppression systems which
are suitable for the material being processed."
5. Repetitive motions hazards
-"While using a sander or polisher, the operator should
adopt a comfortable posture whilst maintaining secure
footing and avoiding awkward or off-balance postures. The
operator should change posture during extended tasks;
this can help avoid discomfort and fatigue."
-"If the operator experiences symptoms such as persistent
or recurring discomfort, pain, throbbing, aching, tingling,
numbness, burning sensations or stiffness, these warning
signs should not be ignored. The operator should tell the
employer and consult a qualified health professional."
6. Accessory hazards
-"Disconnect the sander or polisher from the energy supply
before fitting or changing the inserted tool or accessory."
-"Avoid direct contact with the inserted tool during and after
use, as it can be hot or sharp."
-"Use only sizes and types of accessories and consum-
ables that are recommended by the manufacturer of tool;
do not use other types or sizes of accessories or consum-
ables.
-"Grinding wheels and cutting-off tools shall not be used."
-"Check that the maximum operating speed of the inserted
tool (flap wheels, abrasive belts, fibre discs,backing pads,
etc.), is higher than the rated speed of the tool."
-"Self-fixing sander discs shall be placed concentrically on
the supporting pad."
7. Workplace hazards
-"Slips, trips and falls are major causes of workplace injury.
Be aware of slippery surfaces caused by use of the tool
and also of trip hazards caused by the air line or hydraulic
hose."
-"The sander or polisher is not intended for use in poten-
tially explosive atmospheres and is not insulated against
contact with electric power."
-"Ensure that there are no electrical cables, gas pipes,
etc., which can cause a hazard if damaged by use of the
tool."
Safety Precautions
3
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

8. Dust and fume hazards
-"Dust and fumes generated when using tool can cause ill
health (for example cancer,
birth defects, asthma and/or dermatitis); risk assessment
and implementation of appropriate controls for these
hazards are essential."
-"Risk assessment should include dust created by the use
of the tool and the potential for disturbing existing dust."
-"Operate and maintain the sander or polisher as recom-
mended in these instructions, to minimize dust or fume
emissions."
-"Direct the exhaust so as to minimize disturbance of dust
in a dust-filled environment."
-"Where dust or fumes are created, the priority shall be to
control them at the point of emission."
-"All integral features or accessories for the collection,
extraction or suppression of airborne dust or fumes should
be correctly used and maintained in accordance with the
manufacturer's instructions."
-"Select, maintain and replace the consumable/inserted
tool as recommended in the instruction handbook, to
prevent an unnecessary increase in dust or fumes."
-"Use respiratory protection in accordance with employer's
instructions and as required by occupational health and
safety regulations."
9. Noise hazards
-"Exposure to high noise levels can cause permanent,
disabling hearing loss and other problems, such as tinnitus
(ringing, buzzing, whistling or humming in the ears).
Therefore, risk assessment and implementation of
appropriate controls for these hazards are essential."
-"Appropriate controls to reduce the risk can include
actions such as damping materials to prevent workpieces
from “ringing”."
-"Use hearing protection in accordance with employer's
instructions and as required by occupational health and
safety regulations."
-"Operate and maintain the sander or polisher as recom-
mended in the instruction handbook, to prevent an
unnecessary increase in the noise level."
-"Select, maintain and replace the consumable/inserted
tool as recommended in the instruction handbook, to
prevent an unnecessary increase in noise."
-"If the sander or polisher has a silencer, always ensure it
is in place and in good working order when the tool is
being operated."
10. Vibration hazards
-"Exposure to vibration can cause disabling damage to the
nerves and blood supply of the hands and arms.”
-"Wear warm clothing when working in cold conditions and
keep your hands warm and dry."
-"If you experience numbness, tingling, pain or whitening
of the skin in your fingers or hands, stop using the sander
or polisher, tell your employer and consult a physician."
-"Operate and maintain the sander or polisher as recom-
mended in the instruction handbook, to prevent an
unnecessary increase in vibration levels."
-"Hold the tool with a light but safe grip, taking account of
the required hand reaction forces, because the risk from
vibration is generally greater when the grip force is higher."
11. Additional safety instructions for pneumatic power
tools:
-"Air under pressure can cause severe injury:
-always shut off air supply, drain hose of air pressure
and disconnect tool from air supply when not in use,
before changing accessories or when making repairs;
-never direct air at yourself or anyone else;"
-"Whipping hoses can cause severe injury. Always check
for damaged or loose hoses and fittings;”
-"Whenever universal twist couplings (claw couplings) are
used, lock pins shall be installed and whipcheck safety
cables shall be used to safeguard against possible
hose-to-tool or hose-to-hose connection failure;”
-"Do not exceed the maximum air pressure stated on the
tool;"
-"Never carry an air tool by the hose."
12. Operating instructions include, where appropriate:
-instructions for setting up or fixing tool in stable position
as appropriate if type of tool can be mounted;
-assembly instructions, including recommended guards,
accessories and inserted tools;
-an illustrated description of functions;
-limitations on tool use due to environmental conditions;
-instructions for setting and testing;
-general instructions for use, including changing inserted
tools and limits on size and type of workpiece;
-instructions stating that a tool shall not be operated at a
speed exceeding the rated speed
Safety Precautions
4
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

Parts Page
5
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05
ITEM
38
55
56
8.7 (1.0)
60-72 (6.8-8.1)
8.7 (1.0)
TORQUE SETTING
in.- lbs. (N.m)
2
1
33
3
4
5
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
24
25
26
27
28
29
30
32
27
34
35
36
37
38
27
39
25
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
61
21
22
23
31

Parts List
Item No. Part No. Description Qty.
1673-A0040 EXTERNAL RETAINING RING 1
2673-A0021 BEARING - 6000ZZ 1
3673-B0017 REAR ENDPLATE 1
4673-B0011 CYLINDER ASSEMBLY 1
5673-A0042 O-RING 1
6673-B0005 MACHINED ROTOR 1
7673-A0010-1 VANE 5
8673-A0041 WOODRUFF KEY 1
9673-B0016 FRONT ENDPLATE 1
10 673-A0019 BEARING 1
11 673-P10 LOCK RING ASSEMBLY 1
12 673-A2543 SPINDLE BEARING DUST SHIELD 1
13 673-B0084 3" x 3/32 in. ORBIT LW ROS AirSHIELD PLUS SHAFT BALANCER OPT
13 673-B0309 3" x 3/16 in. ORBIT LW ROS AirSHIELD PLUS SHAFT BALANCER OPT
14 673-A0122 FILTER MATERIAL 1
15 673-A0121 DUCKBILL CHECK VALVE 1
16 673-A0120 VALVE RETAINER 1
17 673-A0090 RETAINING RING 1
18 673-A0938 DOUBLE ROW ANGULAR CONTACT BEARING-1SEAL (5001RS) 1
19 673-A0016 SPACER 1
20 673-A2542 SPINDLE BEARING DUST SHIELD 1
21 673-A0017 BELLEVILLE WASHER 1
22 673-A0018 RETAINING RING 1
23 673-B0312 SPINDLE 1
24 673-G0108 GRIP 1
25 673-A0039 INTERNAL RETAINING RING 2
26 673-F0001 SPEED CONTROL 1
27 673-A0043 O-RING 3
28 _ LEVER FOR CLAYTON ROS (3/32in ORBIT) OPT
28 673-F0088 LEVER FOR CLAYTON ROS (3/16in ORBIT) OPT
29 673-A0031 LEVER SPRING PIN 1
30 673-G0107 MACHINED HOUSING 1
31 673-H0008 CV,SGV SHROUD 3" (Black) 1
32 673-H0007 CV,SGV SHROUD 3" (Black) 1
33 673-A0146 WRENCH (17 mm) 1
34 NA 1 PAD SUPPLIED WITH EACH TOOL OPT
35 673-A0008 VALVE STEM ASSEMBLY 1
36 673-A0015 VALVE SLEEVE 1
37 HN2-04CA Hex. Nut (M4) 1
38 S6-0430A HEX.SOCKET BUTTON HEAD SCREW (M4x30) 1
39 673-F0003 SPEED CONTROL 1
40 673-G0044 EXHAUST CHAMBER 1
6
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

Parts List
Item No. Part No. Description Qty.
41 673-A2204 O-RING (9.5x1mm) 1
42 673-A2484 O-RING (24x1mm) 1
43 673-F0013 MUFFLER 1
44 673-F0008 MUFFLER COVER 1
45 673-F0011 MUFFLER O8.5*O21*T6mm 1
46 673-F0012 O-RING(O/R 20*1 N70) 1
47 673-F0009 EXHAUST CAP,BUFFER 1
48 673-F0010 VARIABLE EXHAUST 1
49 673-A0009 VALVE SEAT 1
50 673-A0007 VALVE 1
51 673-F0094 VALVE SPRING 1
52 673-G0011 END CAP 1
53 673-F0086 LOGO INSERT-END CAP 1
54 673-A0044 14.0x1.5 O-RING 1
55 673-A2475 INLET BUSHING ASSEMBLY ELITE 1
56 S6-0410A HEX.SOCKET BUTTON HEAD SCREW (M4x10) 3
57 673-F0081 SNAP-IN VAC COVER PLATE(NV) 1
58 673-G0035 3" SWIVEL EXHAUST FITTING (Black)(SGV) OPT
59 673-G0034 3" SWIVEL EXHAUST FITTING (Black)(CV) OPT
60 673-F0117 SWIVEL EXHAUST FITTING (Black)(CV) OPT
7
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

*The values stated in the table are from laboratory testing in conformity with stated codes and standards and are not sufficient for risk evaluation. Values measured
in a particular work place may be higher than the declared values. The actual exposure values and amount of risk or harm experienced to an individual is unique to each
situation and depends upon the surrounding environment, the way in which the individual works, the particular material being worked, work station design as well as upon
the exposure time and the physical condition of the user. CLAYTON cannot be held responsible for the consequences of using declared values instead of actual
exposure values for any individual risk assessment.
Specifications subject to change without prior notice.
Further occupational health and safety information can be obtained from the following websites:
http://europe.osha.eu.int (Europe)
http://www.osha.gov (USA)
Product Configuration and Specifications
12,000 RPM, 3 in. Low Profile Ergolite Random Orbital Sander
Note: All Self Generated Vacuum machines use Ø 1 in. (Ø 28 mm) Vacuum Hose Fittings Standard. Ø ¾ in. (Ø 19 mm)
is available. All Central Vacuum machines use Ø ¾ in. (Ø 19 mm) Vacuum Hose Fittings Standard. Ø 1 in. (Ø 28 mm)
is available. All 3” machines are shrouded with 1/4-20 male pad attachment.
The noise test is carried out in accordance with EN ISO 15744:2008 Measurement of noise emission from hand-held non-electric power tools.
The vibration test is carried out in accordance with EN 28662-1. Hand-held portable power tools – Measurement of vibration at the handle.
Part 1: General and EN 8662-8, 1997. Hand-held portable power tools – Measurement of vibration at the handle. Part 8: Polishers and rotary,
ergolite orbital and ergolite random orbital sanders
Orbit Pad
Face
Model
Number
Vac
Type
Product Net
Weight
Pound (kg)
Height
inch (mm)
Length
inch (mm)
Power HP
(watts)
Air
Consumption
scfm (LPM)
Noise Level
dBA
Pressure
(Power)
Vibration
Level m/s²
Uncertainty
K m/s²
3/32 in.
(2.5 mm)
Vinyl
Non-
Vacuum 1.27 (0.58) 3.6 (93.5) 6.0 (152.5) .30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
.30 (223)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
17 (481)
75 (86) 2.69 0.76
Central
Vacuum 1.40 (0.63) 3.6 (93.5) 7.7 (196.5) 74 (85) 2.13 0.71
Self-Gen
Vacuum
Non-
Vacuum
Central
Vacuum
Self-Gen
Vacuum
Non-
Vacuum
Central
Vacuum
Self-Gen
Vacuum
Non-
Vacuum
Central
Vacuum
Self-Gen
Vacuum
1.41 (0.64) 3.6 (93.5) 7.8 (199.5)
6.0 (152.5)
7.7 (196.5)
7.8 (199.5)
6.0 (152.5)
7.7 (196.5)
7.8 (199.5)
6.0 (152.5)
7.7 (196.5)
7.8 (199.5)
79 (90)
75 (86)
74 (85)
79 (90)
2.72 0.76
2.69 0.76
2.13 0.71
2.72 0.76
Hook
1.27 (0.58) 3.6 (93.5)
1.40 (0.63) 3.6 (93.5)
1.41 (0.64) 3.6 (93.5)
3/16 in.
(5.0 mm)
Vinyl
1.47 (0.66) 3.6 (93.5) 75 (86) 2.72 0.76
1.60 (0.72) 3.6 (93.5) 74.6 (85.5) 2.61 0.75
1.62 (0.73) 3.6 (93.5) 81.5 (92.5)
75 (86)
74.6 (85.5)
81.5 (92.5)
2.64 0.76
2.72 0.76
2.61 0.75
2.64 0.76
Hook
1.47 (0.66) 3.6 (93.5)
1.60 (0.72) 3.6 (93.5)
1.62 (0.73)
770-12310S
770-12311S
770-12313S
770-12310J
770-12311J
770-12313J
770-12300S
770-12301S
770-12303S
770-12300J
770-12301J
770-12303J 3.6 (93.5)
8
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

Work Stations
Putting the Tool into Service
Operating Instructions
1) Read all instructions before using this tool. All operators
must be fully trained in its use and aware of these safety
rules. All service and repair must be carried out by
trained personnel.
2) Make sure the tool is disconnected from the air supply.
Select a suitable abrasive and secure it to the back-up
pad. Be careful and center the abrasive on the back-up
pad.
3) Always wear required safety equipment when using this
tool.
4) When sanding always place the tool on the work then
start the tool. Always remove the tool from the work
before stopping. This will prevent gouging of the work
due to excess speed of the abrasive.
5)
adjusting or removing the abrasive or back-up pad.
6)
of torque reaction developed by the sander.
7) Use only correct spare parts.
8)
9)
the tool by its hose; always be careful to prevent the tool
from being started when carrying the tool with the air
supply connected.
10) Dust can be highly combustible. Vacuum dust collection
bag should be cleaned or replaced daily. Cleaning or
replacing of bag also assures optimum performance.
11) Do not exceed maximum recommended air pressure.
Use safety equipment as recommended.
12) The tool is not electrically insulated. Do not use where
there is a possibility of coming into contact with live
electricity, gas pipes, water pipes, etc. Check the area of
operation before operation.
The tool is intended to be operated as a hand held tool. It is
always recommended that the tool be used when standing
grip and footing and be aware that the sander can develop a
torque reaction. See the section “Operating Instructions”.
Use a clean lubricated air supply that will give a measured
air pressure at the tool of 90 psig (6.2 bar) when the tool is
running with the lever fully depressed. It is recommended
to use an approved 3/8 in. (10 mm) x 25 ft (8 m) maximum
length airline. It is recommended that the tool be connected
to the air supply as shown in Figure 1.
Do not connect the tool to the airline system without incorpo-
rating an easy to reach and operate air shut off valve. The air
supply should be lubricated. It is strongly recommended that
in Figure 1 as this will supply clean, lubricated air at the
correct pressure to the tool. Details of such equipment can
be obtained from your supplier. If such equipment is not used
then the tool should be manually lubricated
To manually lubricate the tool, disconnect the airline and put
2 to 3 drops of suitable pneumatic motor lubricating oil such
as Fuji Kosan FK-20, Mobil ALMO 525 or Shell TORCULA®
32 into the hose end (inlet) of the machine. Reconnect tool to
the air supply and run tool slowly for a few seconds to allow
air to circulate the oil. If the tool is used frequently, lubricate
it on a daily basis or lubricate it if the tool starts to slow or
lose power.
It is recommended that the air pressure at the tool be 90 PSI
(6.2 Bar) while the tool is running so the maximum RPM is not
exceeded. The tool can be run at lower pressures but should
never be run higher than 90 PSI (6.2 Bar). If run at lower pres-
sure the performance of the tool is reduced.
13) Take care to avoid entanglement with the moving parts
of the tool with clothing, ties, hair, cleaning rags, etc. If
entangled, it will cause the body to be pulled towards the
work and moving parts of the machine and can be very
dangerous.
14) Keep hands clear of the spinning pad during use.
15) If the tool appears to malfunction, remove from use im-
mediately and arrange for service and repair.
16) Do not allow the tool to free speed without taking precau-
tions to protect any persons or objects from the loss of
the abrasive or pad.
Closed Loop Pipe System
Sloped in the direction
of air flow
Drain Leg
Ball Valve
To Tool Station
Filter
Drain Valve
Regulator
Lubricator
Ball
Valve
Ball Valve
Air Flow
Air Dryer
Air Compressor
and Tank
Air Hose
To Coupler
at or near Tool
Figure 1
Back-Up Pads
Part #
672-300S
672-300J
672-301S
672-301J
Description
3" Low Profile (1/4-20), Non-Vacuum, vinyl face
3" Low Profile (1/4-20), Non-Vacuum, j-hook face
3" Low Profile (1/4-20), Vacuum, vinyl face
3" Low Profile (1/4-20), Vacuum, j-hook face
NSN
_
_
_
4130-01-459-5206
CLAYTON back-up pads are perfectly mated for use on the CLAYTON
Sander. Constructed from premium, industrial-quality materials and
featuring a riveted fiberglass and steel hub with molded urethane,
their durability and precise construction are the ideal complement to
the performance of the CLAYTON Sander. See “Product Configuration/
Specifications” Table for the correct replacement pad for a particular
model.
9
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05

NOTICE: To receive any expressed or implied warranty, the tool must be repaired by an authorized Service Center.
The 3 in. (77 mm) Ergolite Random Orbital Sander Service Instructions section provided is for use after completion
of the warranty period.
12,000 RPM 3 in. (77 mm) Ergolite ROS Service Instructions
Motor Disassembly:
1. Lightly secure the tool in a vise using the T-7 Service Col-
lar or padded jaws. Use a 17 mm Pad Wrench to secure
the Spindle and spin the Pad counter clock-wise off the
spindle.
2. Remove the Lock Ring with the T-6 Motor Lock Ring
Wrench/Spindle Puller Tool. The motor assembly can now
be lifted out of the Housing. Remove the O-Ring from the
Lock Ring.
3. Secure the motor assembly by clamping the Shaft
Balancer in a padded jaw vise and remove the Retaining
Ring from the end of the Shaft Balancer and the O-ring
from the Cylinder.
4. Remove the Rear Endplate. This may require support-
ing the Rear Endplate with a bearing separator. Use a
light press force to push the Shaft Balancer through the
Bearing. Then remove the Cylinder, Vanes and the Rotor.
Remove the Key from the Shaft Balancer. Support the
Front Endplate with a bearing separator and use a light
press force to push the Shaft Balancer through the bear-
ing. It may be necessary to remove the Bearing with a
bearing separator if it came out of the Front Endplate and
stuck to the shaft of the Shaft Balancer.
5. Remove the Bearing(s) from the Endplates by using
the T-8 Endplate Bearing Removal Tool to press out the
Bearings.
Shaft Balancer and Spindle Disassembly:
1. Grip the shaft end of the Shaft Balancer in a padded vise.
With a thin screwdriver pick out the slotted end of the
Retaining Ring and peel out.
2. Screw the female end of the T-11 5/16-24 to 1/4-20
Adapter into the male end of the Service Wrench. Screw
the Service Wrench assembly into the Spindle Assembly
until hand tight. Apply a gentle heat from a propane torch
or hot air gun to the large end of the Shaft Balancer until
it is about 212° F (100° C) to soften the adhesive. Do not
over heat. Remove the Spindle Assembly by using the
Slider to give sharp outward blows to the Spindle. Allow
the parts to cool so they are safe to handle.
3. Remove the Retaining Ring from the Spindle Assembly.
Use a small Bearing Separator to remove the Bearing,
Shim, Bearing, Shim and the Washer from the Spindle
Assembly.
ASSEMBLY INSTRUCTIONS
NOTE: All assembly must be done with clean dry parts and
all bearings are to be pressed in place by the correct tools
and procedures as outlined by the bearing manufacturers.
Housing Assembly:
1. Install Throttle Lever into Housing with Spring Pin.
2. Lightly grease the O-Ring and place it on the Speed Con-
trol. Install the Valve Stem and O-ring (cleaned and lightly
greased) and insert the Speed Control into Housing in the
midway position. Install Retaining Ring.
CAUTION: Make sure the Retaining Ring is completely
snapped into groove in the Housing.
3. Install the Valve Seat, Valve and the Spring. Coat the
threads of the Inlet Bushing Assembly with 1 or 2 drops
of Loctite™ 222 or equivalent non-permanent pipe thread
sealant. Screw the Inlet Bushing Assembly into the inlet
port on the Housing. Torque to 60 in/lbs (6.77 Nm.)
Spindle Bearings, and Shaft Balancer
Assembly:
1. Place the T-5A Spindle Bearing Pressing Tool Base onto
with the spindle pocket facing upward. Place the Spindle
into the spindle pocket with the shaft facing upwards. See
Figures 1 and 2.
2. Place theWasher on the Spindle shaft with the curve of
the Washer facing out so that the outside diameter of the
Washer will contact the outer diameter of the Bearing
(one seal). Lay the Shim on the shoulder of the Spindle.
Place the Bearing (one seal) on the Spindle with the seal
side toward the Washer. NOTE: Make sure that both the
inner and outer races of the Bearings are supported by
the Bearing Press Tool when pressing them into place.
Press the Bearing onto the shoulder of Spindle using
the T-5B Spindle Bearing Pressing Tool Top as shown in
Figure 2.
3. Place the Shim over the Spindle shaft and onto the face
of the Bearing making sure it is on center. Press the
(no seals/shields) Bearing down using the T-5A Spindle
Bearing Pressing Tool Top, being careful to make sure
the Shim is still centered on the vertical axis of the
Spindle shaft and Bearing. See Figure 3. NOTE: When
the Spindle Assembly is done correctly, the Bearings will
rotate freely but not loosely and the Shim can be moved
but will not slide or move by gravity.
4. Secure the Retaining Ring onto the Spindle Assembly
making sure it is completely snapped into the groove. Set
the Spindle Assembly aside.
5. Take the Filter and center it on the small bore that
Valve into the bore so it is oriented correctly, then press
of the bearing bore.
6. Apply a pin head size drop of #271 Loctite® or equivalent
to the outside diameter of each of the bearings on the
Spindle Assembly. Spread the drop of bearing locker
around both bearings until distributed evenly. CAUTION:
Only a very small amount of bearing locker is needed
to prevent rotation of the bearing OD. Any excess will
into the bore of the Shaft Balancer and secure with the
Retaining Ring. CAUTION: Make sure that the Retaining
Ring is completely snapped into the groove in the Shaft
Balancer. Allow the adhesive to cure.
DISASSEMBLY INSTRUCTIONS
Changing Grips:
1. The Grip has two “tabs” that wrap around the body of the
sander under the inlet and exhaust. With a small screwdriver
pick out one of the “tabs” of the Grip, and then continue to go
underneath the grip with the screwdriver and pry the Grip off
the sander. To install a new Grip, hold the Grip by the tabs
making them face outward, align the Grip and slide it under
the Throttle Lever then press the Grip down until it seats onto
the top of the sander. Make sure the two “tabs” seat under the
inlet and exhaust.
10
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[phone] • www.VacuumSanding.com
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Revision 2019-05

Motor Assembly:
1. Use the larger end of the T-13 Bearing Press Sleeve to
Press the front Bearing (with 2 Shields) onto the shaft of
the Shaft Balancer.
2. Slide the Front Endplate with the bearing pocket fac-
ing down onto the Motor Shaft. Gently press the Front
Endplate onto the front Bearing using the larger end of
the T-13 Bearing Press Sleeve until the front Bearing is
seated in the bearing pocket of the Front Endplate. CAU-
TION: Only press just enough to seat the bearing into the
pocket. Over-pressing can damage the bearing.
3. Place the Key into the groove on the Shaft Balancer.
Place the Rotor onto the shaft of the Shaft Balancer, mak-
place in the slots in the Rotor. Place the Cylinder As-
sembly over the Rotor with the shorter end of the Spring
Pin engaging the blind hole in the Front Endplate. NOTE:
The Spring Pin must project .060 in. (1.5 mm) above the
Endplate with the T-1B Bearing Press Tool. Make sure the
T 1B Press Tool is centered on the O.D. of the outer race.
over the Shaft Balancer using the small end of the T-13
Bearing Press Sleeve. The sleeve should press only the
inner race of the bearing. IMPORTANT: The Rear End-
plate and Bearing Assembly is pressed correctly when the
Cylinder is squeezed just enough between the Endplates
to stop it from moving freely under its own weight when
the shaft is held horizontal, but be able to slide between
the Endplates with a very light force. If pressed to tightly
the motor will not run freely. If the pressed assembly is to
loose, the motor will not turn freely after assembly in the
Housing.
6. Secure the assembly by placing the Retaining Ring in the
groove of the Shaft Balancer. CAUTION: The Retaining
Ring must be placed so that the middle and two ends of
-
tions must be securely “snapped” into the groove in the
Shaft Balancer by pushing on the curved portions with a
small screwdriver.
7. Carefully screw the Lock Ring into the Housing using the
T-6 Motor Lock Ring Wrench. Torque to 60 in/lbs (6.77
engagement is to turn the lock ring counter clockwise
with the service tool while applying light pressure. You
will hear and feel a click when the lead thread of the lock
ring drops into the lead thread of the housing, then turn
clockwise to tighten.
8. Spin on a new Pad and hand tighten it using a 17 mm
Pad Wrench.
Testing:
Place 3 drops of quality pneumatic air tool oil directly into
the motor inlet and connect to a 90 psig (6.2 bar) air sup-
ply. The tool should run between 9,500 RPM and 10,500
for 10,000 RPM machines or 11,500 and 12,500 RPM for
12,000 RPM machines when the air pressure is 90 psig
(6.2 bar) at the inlet of the tool while the tool is running
at free speed. This free speed will be about 500 RPM to
1,000 RPM less when a Vacuum or Hook Face Pad is used
because of wind resistance. This will not affect performance
when sanding.
* Loctite® is a registered trademark of the Loctite Corp.
Press Tool Top
Press Tool Base
Figure 1 Figure 2
Bearing
Washer
Spindle
Shim Bearing
Shim
Figure 3
11
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[phone] • www.VacuumSanding.com
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Revision 2019-05

Symptom Possible Cause Solution
Low Power and/or Low Free
Speed
Check air line pressure at the Inlet of the
Sander while the tool is running at free
speed. It must be 90 psig (6.2 Bar).
See the “Housing Disassembly” section
cleaning solution until all contaminates
and obstructions have been removed. If
(See the “Housing Assembly” Section).
Plugged Inlet Screen
Clean the Inlet Screen with a clean, suit-
able cleaning solution. If Screen does
not come clean replace it.
One or more Worn or Broken Vanes
Install a complete set of new Vanes
(all vanes must be replaced for proper
operation). Coat all vanes with quality
pneumatic tool oil. See “Motor Disas-
sembly” and “Motor Assembly”.
Internal air leakage in the Motor Housing
indicated by higher than normal air con-
sumption and lower than normal speed.
Check for proper Motor alignment and
Lock Ring engagement. Check for
damaged O-Ring in Lock Ring groove.
Remove Motor Assembly and Re-Install
the Motor Assembly. See “Motor Disas-
sembly” and “Motor Assembly”.
Motor Parts Worn Overhaul Motor. Contact authorized
Service Center.
Worn or broken Spindle Bearings
Replace the worn or broken Bear-
ings. See “Shaft Balancer and Spindle
Disassembly” and “Spindle Bearings,
Shaft Balancer Assembly”.
Air leakage through the Speed
Control and/or Valve Stem.
Dirty, broken or bent Valve Spring, Valve
or Valve Seat.
Disassemble, inspect and replace worn
or damaged parts. See Steps 2 and 3 in
“Housing Disassembly” and Steps 2 and
3 in “Housing Assembly”.
Vibration/Rough Operation
Incorrect Pad Only use Pad Sizes and Weights de-
signed for the machine.
Addition of interface pad or other material
Only use abrasive and/or interface
designed for the machine. Do not attach
anything to the Sanders Pad face that
with the Pad and Sander.
Improper lubrication or buildup of foreign
debris.
Disassemble the Sander and clean in a
suitable cleaning solution. Assemble the
Sander. (See “Service Manual”)
Worn or broken Rear or Front Motor
Bearing(s)
Replace the worn or broken Bearings.
See “Motor Disassembly” and “Motor
Assembly”.
For vacuum machines it is possible to
have too much vacuum while sanding on a
sanding surface.
For SGV machines add extra washer(s)
to the pad spindle to increase the gap
between the pad and shroud. For CV
machines reduce vacuum through
the vacuum system and/or add extra
washer(s) to the pad.
Troubleshooting Guide
12
Copyright © 1984-2016 CLAYTON Associates, Inc.
[phone] • www.VacuumSanding.com
B-X3CT30-8
Revision 2019-05