Clayton TwoHAND User manual

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
i
5 in. (125 mm) and 6 in. (150 mm)
TwoHAND™ 12,000 RPM
RANDOM ORBITAL SANDER
MANUAL
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,
Specications Table and Trouble Shooting Guide.
Declaration of Conformity
Clayton Associates, Inc. 1650 Oak Street Lakewood, NJ 08701 USA
declare on our sole responsibility that the products
5 in. (125 mm) and 6 in. (150 mm) TwoHAND™ Random Orbital Sanders (See Product “Specications” 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
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
Clayton Associates, Inc.
1650 Oak Street
Lakewood, NJ 08701 USA
TEL [phone]
www.VacuumSanding.com
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 5/27/10 James E. Clayton
Original Instructions

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
ii

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
1
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
1) General Industry Safety & Health Regulations, Part 1910, OSHA
2206, available from: Superintendent of Documents; Government
Printing Ofce; 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.
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 specied
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.
The tool is intended to be operated as a hand held tool. It is always
recommended that the tool be used when standing on a solid oor. It
can be in any position but before any such use, the operator must be
in a secure position having a rm 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 pres-
sure 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 incorporating an
easy to reach and operate air shut off valve. The air supply should
be lubricated. It is strongly recommended that an air lter, regulator
and lubricator (FRL) be used as shown 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 air tool oil (Clayton P/N 678-20451) 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 is 90 psig (6.2 bar)
while the tool is running. The tool can run at lower pressures but never
higher than 90 psig (6.2 bar).
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 abra
sive 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) Always remove the air supply to the sander before t-
ting, adjusting or removing the abrasive or back-up pad.
6) Always adopt a rm footing and/or position and be
aware of torque reaction developed by the sander.
7) Use only correct spare parts.
8) Always ensure that the material to be sanded is rmly
xed to prevent its movement.
9) Check hose and ttings regularly for wear. Do not carry
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.
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 precautions to protect any persons or objects from the loss of the abrasive or pad.
Putting the Tool into Service
Operating Instructions
Please Read and Comply with
Proper Use of Tool
Work Stations

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
2
Assembly Drawing
1
2
3
4
5
7
6
8
9
10
11
13
17
18
19
20
21
22
14
15
16
23
24
25 26
27
28
29
32
31
33
34
36
35
37
38
39
40
41
42
43
44
45
46
47
48
49
25
50
53
52 54 55 56
52
53
57
58
59
61
60
62
63
52
51
64
TO VACUUM
SYSTEM FOR
CENTRAL
VACUUM
65
66
67
68
30
12
69
70
REVISION RECORD
R DESCRIPTION / DATE
A
-RELEASE FOR PRODUCTION
RAG 11/12/08 PWH 11/12/08
B
-ITEM 30 XPA2398 WAS XPA2159
-ITEM 30 XPA2400 WAS XPA2160
-XPA2158 WAS REMOVED
RAG 03/17/10 MDR 03/18/10
C
-ITEMS 69 & 70 WERE NOT ON
MCC 03/08/12 FNK 03/08/12
IT P/N DESCRIPTION QTY
1 XPA0040 EXTERNAL RETAINING RING 1
2XPA0021
10 X 26 X 8 BEARING - 2 SHIELDS 1
3XPB0017
REAR ENDPLATE 1
4XPA0441
50.0 X 36.0 mm CYLINDER ASSEMBLY 1
5XPA0042
5 mm x 2.0 mm O-RING 1
6XPB0118
Ø 50.0 mm x 36 mm MOTOR MACHINED ROTOR 1
7XPA0445
VANE FOR Ø 50.0 mm x 36.0 mm MOTOR 5
8XPA0041
3 mm x 13 mm WOODRUFF KEY 2
9XPB0016
FRONT ENDPLATE 1
10 XPA0019
12 X 28 X 8 BEARING - 2 SHIELDS 1
11 XPA0045
39.4 mm x 3.1 mm O-RING 1
12 XPA0001
LOCK RING 1
13 XPB0206
TwoHAND 125 x 2.5 mm (5 x 3/32 in.) ORBIT ROS AirSHIELD™ SHAFT
BALANCER
1
13 XPB0207
TwoHAND 125 x 5.0 mm (5 x 3/16 in.) ORBIT ROS AirSHIELD™ SHAFT
BALANCER
1
13 XPB0189
TwoHAND 125 x 10 mm (5 x 3/8 in.) ORBIT ROS AirSHIELD™ SHAFT
BALANCER
1
13 XPB0205
TwoHAND 150 x 2.5 mm (6 x 3/32 in.) ORBIT ROS AirSHIELD™ SHAFT
BALANCER
1
13 XPB0187
TwoHAND 150 x 5.0 mm (6 x 3/16 in.) ORBIT ROS AirSHIELD™ SHAFT
BALANCER
1
13 XPB0188
TwoHAND 150 X 10 mm (6 x 3/8 in.) ORBIT ROS AirSHIELD™ SHAFT
BALANCER
1
14 XPA0122
FILTER 1
15 XPA0121
DUCKBILL CHECK VALVE 1
16 XPA0120
VALVE RETAINER 1
17 XPA0090
11.9 mm (15/32 in.) RETAINING RING 1
18 XPA0751
12 x 32 x 15.9 DOUBLE ROW ANGULAR CONTACT BEARING - 1 SEAL 1
19 XPA1767
SPACER 12.1 ID x 22.0 OD x 0.2 THK 1
20 XPA1024
BELLEVILLE WASHER 1
21 XPB0208
SPINDLE 1
22 XPA1025
RETAINING RING 1
23 XPA0022
24 mm PAD WRENCH 1
24
NA 1 Pad Supplied With Each Tool (Type Determined By Model) 1
25 XPA2058 M8 THREADED PLUG - PMS 123C YELLOW 2
26 XPB0395
36.0 mm RH VACUUM CLAYTON HOUSING 1
27 XPA0032
MUFFLER INSERT (for 10,000 RPM Machines) 1
28 XPA1218
TOP HOUSING SEAL (NV & CV Machines) 1
29 XPB0290
36.0 mm MOTOR HOUSING SEAL 1
30 XPA2398 CLAYTON ROS 12,000 RPM 3/16 in. ORBIT THROTTLE SAFETY LEVER
ASSEMBLY - TwoHAND
1
30 XPA2400 CLAYTON ROS 12,000 RPM 3/8 in. ORBIT THROTTLE SAFETY LEVER
ASSEMBLY - TwoHAND
1
31 XPA2062 HANGER - PMS 123C YELLOW 1
32 XPA1865
SPACER RING 2
33 XPB0356
36.0 mm DIE-CAST MACHINE MOTOR HOUSING W/SIDE HANDLE
MOUNTING STUDS
1
34 XPA0004
CYLINDER SPRING PIN 1
35 XPA0655
VALVE STEM ASSEMBLY 1
36 XPA0015
VALVE SLEEVE 1
37 XPA0009 VALVE SEAT 1
38 XPA0007 VALVE 1
39 XPA0014 VALVE SPRING 1
40 XPA0730
AIRLINE SEAL ASSEMBLY 1
41 XPA0500
EXHAUST GASKET 1
42 XPB0181
36.0 mm MOTOR SGV EXHAUST NOZZLE 1
43 XPB0182
NV/CV EXHAUST NOZZLE 1
44 XPA0664
M4 X 8 HEX SOCKET BUTTON HEAD CAP SCREW 3
45 XPA0517
EXHAUST TUBING (NV & CV Machines) 1
46 XPA0516
TUBING CLAMP (NV & CV Machines) 1
47 XPA0511
INLET TUBING 1
48
XPC0153 TwoHAND™ 5/6 in. BUFFER/NV SHROUD 1
49 XPA2060
TwoHAND™ 5 in. MULTI-HOLE/LP SHROUD - PMS 123C YELLOW 1
49 XPA2061
TwoHAND™ 6 in. MULTI-HOLE/LP SHROUD - PMS 123C YELLOW 1
49
XPC0147 5 in. TAPERED EDGE SKIRT 1
49
XPC0146 6 in. TAPERED EDGE SKIRT 1
50 XPA1998
CLAYTON SIDE HANDLE 1
51 XPB0472
36.0 mm LH PMS 123 YELLOW HOUSING WITH BLACK OVERMOLD 1
52 XPA1398
SCREW, BUTTON HEAD TORX M4.0 X 15 mm BLACK 5
53 XPA1430
SCREW, BUTTON HEAD TORX M4.0 X 30 mm BLACK 7
54 XPA0043
9 mm x 1.5 mm O-RING 1
55 XPA2059
TwoHAND SPEED CONTROL - PMS 123C YELLOW 1
56 XPA0039
INTERNAL RETAINING RING 1
57 XPA0510
2 HAND INLET CAPTIVE RING 1
58 XPA0509
7.6 mm x 1.78 mm 0-RING 1
59 XPA0628
O-RING (NV & CV Machines) 1
60 XPA0776
MUFFLER (NV & CV Machines) 2
61 XPA0731
INLET/EXHAUST END CAP ASSEMBLY FOR NV MACHINES 1
62 XPA2066
INLET/EXHAUST END CAP ASSEMBLY FOR SGV AND CV MACHINES - PMS
123 YELLOW 1
63 XPA0013
1/4-18 NPT INLET BUSHING ASSEMBLY 1
64 XPA0392
Ø1 in. VAC HOSE TO Ø1 in./28 mm x 1 1/2 in. ADAPTOR COUPLING AND
AIRLINE ASSEM
1
65 XPA0623
1 in. (28 mm) HOSE SEAL-TwoHAND™ (SGV Machines) 1
66 XPA0412
Ø 1 in. VAC HOSE TO DOUBLE BAG FITTING AND AIRLINE ASSY 1
67
XPC0110 VACUUM BAG 1
68
XPC0109 VACUUM BAG INSERT 1
69 XPA2541
FRONT BEARING DUST SHIELD 1
70 XPA2540
TwoHAND SPINDLE BEARING DUST SHIELD 1
ITEM NO. TORQUE SETTINGS in.-lbs (N-m)
12 55 - 65 (6.2 - 7.3)
43 21 - 30 (2.4 - 3.4)
52 27 - 30 (3.0 - 3.4)
53 29 - 33 (3.3 - 3.7)
63 60 - 72 (6.8 - 8.1)
XPD0066
P/N
TITLE
DRWN BY / DATE
MATERIAL
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
PROPERTY OF X'POLE PRECISION TOOLS INC. ANY REPRO-
DUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN
PERMISSION OF X'POLE PRECISION TOOLS INC. IS PROHIBITED.
CKD BY / DATE
ENG APP / DATE
STD TOL
.X +/-
.XX +/-
.XXX +/-
XX/XX +/-
ANGLES +/-
0.1
0.05
NA
NA
0.5°
X'POLE
PRECISION
TOOLS INC.
RAG
11/12/08 11/12/08
PWH
SEE BOM
CLAYTON 5 & 6 in. (125 & 150 mm) 12,000
RPM TwoHAND™ ROS

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
3
Parts List
Item No. Part No. Description Qty.
1 673-A0040 EXTERNAL RETAINING RING 1
2 673-A0021 BEARING - 2 SHIELDS 1
3 673-B0017 REAR ENDPLATE 1
4 673-A0441 CYLINDER ASSEMBLY 1
5 673-A0042 O-RING 1
6673-B0118 ROTOR 1
7 673-A0445 VANE 5
8 673-A0041 WOODRUFF KEY 2
9 673-B0016 FRONT ENDPLATE 1
10 673-A0019 BEARING - 2 SHIELDS 1
11 673-A0045 O-RING 1
12 673-A0001 LOCK RING 1
13
673-B0206 125 x 2.5 mm (5 x 3/32 in.) ORBIT ROS AirSHIELD™ SHAFT BALANCER 1
673-B0207 125 x 5.0 mm (5 x 3/16 in.) ORBIT ROS AirSHIELD™ SHAFT BALANCER 1
673-B0189 125 x 10 mm (5 x 3/8 in.) ORBIT ROS AirSHIELD™ SHAFT BALANCER 1
673-B0205 150 x 2.5 mm (6 x 3/32 in.) ORBIT ROS AirSHIELD™ SHAFT BALANCER 1
673-B0187 150 x 5.0 mm (6 x 3/16 in.) ORBIT ROS AirSHIELD™ SHAFT BALANCER 1
673-B0188 150 X 10 mm (6 x 3/8 in.) ORBIT ROS AirSHIELD™ SHAFT BALANCER 1
14 673-A0122 FILTER 1
15 673-A0121 DUCKBILL CHECK VALVE 1
16 673-A0120 VALVE RETAINER 1
17 673-A0090 RETAINING RING 1
18 673-A0751 DOUBLE ROW ANGULAR CONTACT BEARING - 1 SEAL 1
19 673-A1767 SPACER 0.2 THK 1
20 673-A1024 BELLEVILLE WASHER 1
21 673-B0208 SPINDLE 1
22 673-A1025 RETAINING RING 1
23 673-A0022 24 mm PAD WRENCH 1
24 NA 1 Pad Supplied With Each Tool (Type Determined By Model) 1
25 673-A2058 THREADED PLUG 2
26 673-B0395 36.0 mm RH VACUUM HOUSING 1
27 673-A0032 MUFFLER INSERT 1
28 673-A1218 TOP HOUSING SEAL (NV & CV Machines) 1
29 673-B0290 MOTOR HOUSING SEAL 1
30 673-A2398 3/16 in. ORBIT THROTTLE SAFETY LEVER ASSEMBLY 1
673-A2400 3/8 in. ORBIT THROTTLE SAFETY LEVER ASSEMBLY 1
31 673-A2062 HANGER 1
32 673-A1865 SPACER RING 2
33 673-B0356 MOTOR HOUSING W/SIDE HANDLE MOUNTING STUDS 1
34 673-A0031 LEVER SPRING PIN 1
35 673-A0655 VALVE STEM ASSEMBLY 1
36 673-A0015 VALVE SLEEVE 1
37 673-A0009 VALVE SEAT 1
38 673-A0007 VALVE 1
39 673-F0094 VALVE SPRING 1
40 673-A0730 AIRLINE SEAL ASSEMBLY 1
41 673-A0500 EXHAUST GASKET 1
42 673-B0181 SGV EXHAUST NOZZLE 1
43 673-B0182 NV/CV EXHAUST NOZZLE 1
44 673-A0664 SCREW 3
45 673-A0517 EXHAUST TUBING (NV & CV Machines) 1
46 673-A0516 TUBING CLAMP (NV & CV Machines) 1
47 673-A0511 INLET TUBING 1
48 673-C0153 5/6 in. BUFFER/NV SHROUD 1
49
673-A2060 5 in. MULTI-HOLE/LP SHROUD 1
673-A2061 6 in. MULTI-HOLE/LP SHROUD 1
673-C0147 5 in. TAPERED EDGE SKIRT 1
673-C0146 6 in. TAPERED EDGE SKIRT 1
50 673-A1998 CLAYTON SIDE HANDLE 1
51 673-B0472 LH HOUSING WITH BLACK OVERMOLD 1
52 673-A1398 SCREW 5
53 673-A1430 SCREW 7
54 673-A0043 O-RING 1
55 673-A2059 SPEED CONTROL 1
56 673-A0039 INTERNAL RETAINING RING 1
57 673-A0510 INLET CAPTIVE RING 1
58 673-A0509 O-RING 1
59 673-A0628 O-RING (NV & CV Machines) 1
60 673-A0776 MUFFLER (NV & CV Machines) 2
61 673-A0731 INLET/EXHAUST END CAP ASSEMBLY FOR NV MACHINES 1
62 673-A2066 INLET/EXHAUST END CAP ASSEMBLY FOR SGV AND CV MACHINES 1
63 673-A0013 INLET BUSHING ASSEMBLY 1
64 673-A0392 Ø 1 in. VAC HOSE TO Ø 1 in./28 mm x 1 1/2 in. ADAPTOR COUPLING AND AIRLINE ASSEM 1
65 673-A0623 1 in. (28 mm) HOSE SEAL (SGV Machines) 1
66 673-A0412 Ø 1 in. VAC HOSE TO DOUBLE BAG FITTING AND AIRLINE ASSY 1
67 673-C0110 VACUUM BAG 1
68 673-C0109 VACUUM BAG INSERT 1
69 673-A2541 FRONT BEARING DUST SHIELD 1
70 673-A2540 TwoHAND SPINDLE BEARING DUST SHIELD 1

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
4
ROS Spindle Bearing Kit
P/N 673-A2525
Sander Spare Parts Kits
Endplate Bearing Kit
P/N 673-A0434
Speed Valve Kit
P/N 673-A2645
Rotor, Vanes and Key Kit
P/N 673-A2528
Drop-in Motor 5x3/16
P/N 673-B0495
Drop-in Motor 6x3/16
P/N 673-B0498
Drop-in Motor 5x3/8
P/N 673-B0496
Drop-in Motor 6x3/8
P/N 673-B0499
(Drop-in motor includes items 1-22,69&70)
In addition to the kits below, please see our complete
General Rebuild Kit P/N 673-B0537 on page 5.
Scaled 50%
1
2
69
REVISION RECORD
RDESCRIPTION / DATE
A-RELEASE FOR PRODUCTION
RAG 01/30/08 PWH 02/13/08
YTQNOITPIRCSEDN/PTI
2RELFFUM6770APX1
1)senihcaMMPR000,01rof(TRESNIRELFFUM2300APX2
1TIKRELFFUMMPR000,21EGATNAVriAROFLEBAL3881APX3
1GABEPAN4
RAG
01/30/08
PWH
02/13/08
REVISED 12/19
- 2 HAND
XPA1877
TOOLS INC.
NA
0.05
P/N
TITLE
DRWN BY / DATE
MATERIAL
.XX +/-
DUCTION IN PART OR ASA WHOLE WITHOUT THE WRITTEN
PROPRIETARY AND CONFIDENTIAL
NA
0.5°
X'POLE PRECISION
/05
PROPERTY OF X'POLE PRECISION TOOLS INC. ANY REPRO-
ANGLES +/-
0.1
PERMISSION OF X'POLE PRECISION TOOLS INC. IS PROHIBITED.
CKD BY / DATE ENG APP / DATE
STD TOL
.X +/- XX/XX +/-
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
.XXX +/-
AirVANTAGE™ 12,000 RPM MUFFLER KIT
SEE BOM
12,000 RPM Mufer Kit
P/N 673-A2524
27
60
60
RAG 01/30/08 PWH 02/13/08
-RELEASE FOR PRODUCTION
A
DESCRIPTION / DATER
REVISION RECORD
TOOLS INC.
RAG
01/30/08
PWH
02/13/08
KIT - 36.0 MM MOTOR
XX/XX +/-
0.05
0.1
XPA1878
P/N
TITLE
DRWN BY / DATE
DUCTION IN PART OR ASA WHOLE WITHOUT THE WRITTEN
.XX +/-
MATERIAL
NA
NA
0.5°
X'POLE PRECISION
PROPERTY OF X'POLE PRECISION TOOLS INC. ANY REPRO-
ANGLES +/-
PROPRIETARY AND CONFIDENTIAL
PERMISSION OF X'POLE PRECISION TOOLS INC. IS PROHIBITED.
CKD BY / DATE ENG APP / DATE
STD TOL
.X +/-
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
.XXX +/-
AirVANTAGE™ ROS SPINDLE BEARING
SEE BOM
18
19
20
70
22
17
1/4-18 NPT Air Inlet Kit
P/N 673-A3203
39
38
40
37
35
36
55
54
56
8
67
RAG 01/31/08 PWH 02/13/08
-RELEASE FOR PRODUCTION
A
DESCRIPTION / DATER
REVISION RECORD
YTQNOITPIRCSEDN/PTI
2YEKFFURDOOWmm31xmm31400APX1
1ROTORDENIHCAMROTOMmm63xmm0.05Ø8110BPX2
5ROTOMmm0.63xmm0.05ØROFENAV5440APX3
4 XPA1887 LABEL FOR AirVANTAGE ROTOR, VANES AND KEYS KIT - 36.0 MM MOTOR 1
1GABEPAN5
01/31/08
PWH
02/13/08
REVISED 12/19
KEYS KIT - 36.0 MM MOTOR
XPA1881
P/N
RAG
NA
NA
TITLE
DRWN BY / DATE
MATERIAL
PROPRIETARY AND CONFIDENTIAL
DUCTION IN PART OR ASA WHOLE WITHOUT THE WRITTEN
.XX +/-
PERMISSION OF X'POLE PRECISION TOOLS INC. IS PROHIBITED.
0.5°
X'POLE PRECISION
/05
PROPERTY OF X'POLE PRECISION TOOLS INC. ANY REPRO-
ANGLES +/-
0.1
0.05
CKD BY / DATE ENG APP / DATE
STD TOL
.X +/- XX/XX +/-
TOOLS INC.
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE
.XXX +/-
AirVANTAGE™ ROTOR, VANES AND
SEE BOM
10

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
5
Clayton Service Tools and Accessories
When a Clayton ROS needs to be serviced, we offer a tool kit to make the disassembly/assembly fast and easy. The Service
Tools are highly recommended for use with the Overhaul Service Kit. NOTICE: To receive any expressed or implied warranty,
the tool must be repaired by an authorized Clayton Service Center. The 5 in. and 6 in. TwoHAND™ Random Orbital Sanders
Service Instructions section provided are for use after completion of the warranty period.
UNIVERSAL SERVICE TOOL KIT
T-6 MOTOR LOCK RING
WRENCH/SPINDLE PULLER
T-8 MOTOR FACE PLATE
BEARING REMOVAL TOOL
T-13 BEARING
PRESS TOOL
T-9 12 mm ID
BEARING PULLER
T-1 ROS SPINDLE
BEARING PRESS TOOLS
DISASSEMBLY INSTRUCTIONS
Motor Disassembly:
To prevent damage to the motor assembly the following
sequence must be followed:
1. Remove the Pad with the 24 mm Pad Wrench.
2. Unscrew the Lock Ring with the T-6 Motor Lock Ring
Wrench/Spindle Puller Tool. The motor assembly and
Lock Ring can now be lifted out of the Motor Housing.
3. Remove the Retaining Ring and the O-Ring from the
Cylinder.
4. Remove the Rear Endplate. This requires supporting
the Rear Endplate using a Bearing Separator and light-
ly pressing the shaft through the Bearing and the Rear
Endplate. Remove the Cylinder and the ve Vanes and
Rotor from the shaft of the Shaft Balancer. Remove the
Keys then press off the Front Endplate (with Bearing),
O-Ring and the Lock Ring. 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 and discard Dust Shield from the Shaft Bal-
ancer.
6. Remove the bearing(s) from the endplates by using the
T-8 Bearing Removal Tool to press out the bearings.
Shaft Balancer and Spindle Disassembly:
1. With a thin screwdriver pick out the slotted end of the
Retaining Ring and peel out.
2. Screw the threaded end of the T-6 Motor Lock Ring
Wrench/Spindle Puller Tool into the Spindle 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 pull the spindle assembly outward. Allow the
parts to cool until they are safe to handle. Do not “bang
out” the spindle assembly using the T-6 Motor Lock
Ring Wrench/Spindle Puller Tool because this could
damage the Bearing.
3. The AirSHIELD™ components are held in place by
the light press t of the Retainer. These components
can be damaged during removal and may need to be
replaced if removed. To remove the Retainer, use an
NOTICE: To receive any expressed or implied warranty, the
tool must be repaired by an authorized Service Center.
The 5 in (127 mm.) and 6 in. (150 mm) TwoHAND™ Ran-
dom Orbital Sander Service Instructions section provided is
for use after completion of the warranty period.
Service Instructions
PN 673-B0537 Clayton General Rebuild Kit Contents
Item Part No. Description Qty.
1 673-A0040 External Retaining Ring 1
17 673-A0090 Retaining Ring 1
2 673-A0021 Bearing – 2 Shields 1
59 673-A0628 O-Ring 1
5 673-A0042 O-Ring 1
54 673-A0043 O-Ring 1
14 673-A0122 Filter 1
15 673-A0121 Check Valve 1
16 673-A0120 Valve Retainer 1
41 673-A0500 Exhaust Gasket 1
35 673-A0655 Valve Stem Assembly 1
40 673-A0730 Airline Seal Assembly 1
6 673-B0118 Rotor 1
7 673-A0445 Vanes 5
8 673-A0041 Key 2
10 673-A0019 Bearing 1
18 673-A0751 Bearing 1
19 673-A1767 Spacer 1
56 673-A0039 Internal Retaining Ring 1
60 673-A0776 Mufer 2
27 673-A0032 Mufer Insert 1
37 673-A0009 Valve Seat 1
38 673-A0007 Valve 1
39 673-F0094 Valve Spring 1
N/A 673-A2152 5/6 in. TwoHand ROS Instructions 1
Clayton™ General Rebuild Kit
The Clayton General Rebuild Kit PN 673-B0537 contains
all the replacement parts that naturally wear over time
and a straightforward manual to make servicing a Clayton
sander simple. Overhauling the Random Orbital Sander
can be made even easier with the use of the above Service
Tools. The Service Tools also reduce the chance of im-
proper assembly.

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
6
o-ring pick or a #8 sheet metal screw to grip and pull
out the Retainer. Remove the Valve and Filter from the
bore in the Shaft Balancer. If the Retainer and Valve
were not damaged, they can be reused. However, the
Filter should be replaced on re-assembly.
4. Remove the Retaining Ring from the Spindle.
5. Remove the bearing from the Spindle. Remove the
Spacer, Dust Shield and Washer from the Spindle.
Discard Dust Shield.
Housing Disassembly:
1. Unscrew the threaded Plug(s) and/or the Handle (if
used) from the Motor Housing.
2. Remove the Hanger and Spacer Ring. (if used)
3. Remove the Retaining Ring. The Speed Control (with
O-Ring) will now pull straight out from the Motor Hous-
ing. Use an o-ring pick to remove the O-Ring from the
Speed Control.
4. Use a T-20 Torx driver to unscrew all Screws.
5. Remove the Housings.
6. Remove the Mufer and Seals from the Housing.
6a. For Non-Vacuum (NV) machines: Remove the End
Cap.
6b. For Central Vacuum (CV) and Self Generated Vacuum
(SGV) machines: Remove the End Cap. Remove the
Hose Seal from the CV/SGV End Cap.
7. Unscrew the Inlet Bushing from the End Cap. Remove
the Mufers, Captive Ring, O-Ring, and O-Ring from
the End Cap.
8a. For NV and CV machines: Remove the exhaust (Tub-
ing, Tubing Clamp, and inlet Tubing from the motor
housing assembly. Separate the exhaust Tubing, Tub-
ing Clamp, and inlet Tubing from each other.
8b. For SGV machines: Remove the inlet Tubing from the
motor housing assembly.
9. Unscrew the three Screws from the motor housing as-
sembly.
10a.For NV and CV machines: Remove the NV/CV Ex-
haust Nozzle and the Gasket from the motor housing
assembly.
10b.For SGV machines: Remove the SGV Exhaust Nozzle
and the Gasket from the motor housing assembly.
11. Press out the Spring Pin from the Motor Housing and
remove the Throttle Lever.
12. Remove the Seal Assembly. This component can
become damaged during removal and will need to be
replaced if damaged.
13. Remove the Spring, Valve, Valve Seat, and the Valve
Stem from the Motor Housing. Use an o-ring pick to
remove the o-ring from the Valve Stem.
14. Remove the Sleeve from the Motor Housing.
15. Remove the Shroud from the Motor Housing.
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. Press the Sleeve ush to the top of the Motor Housing.
Press Tool Top
Press Tool Base
Spacer
Dust Shield
Bearing
Washer
Spindle
T-1B
T-1A

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800-248-8650 • www.VacuumSanding.com
7
2. Lightly grease the o-ring and place it in the groove of
the Valve Stem. Install the Valve Stem into the Sleeve.
3. Install the Valve Seat, the Valve and the Spring. Press
the Seal Assembly into the Motor Housing.
4. Install the Throttle Lever into the Motor Housing with
the Spring Pin.
5. Install the Shroud onto the Motor Housing.
6a. For NV and CV machines: Install the NV/CV Exhaust
Nozzle and the Gasket using the three Screws. Torque
setting to be 21-30 in-lbs (2.4-3.4 N-m). Insert the
exhaust Tubing and the inlet Tubing into the Tub-
ing Clamp. Then insert the exhaust Tubing into the
Exhaust Nozzle and insert the inlet Tubing into the Seal
Assembly.
6b. For SGV machines: Install the SGV Exhaust Nozzle
and Gasket using the three Screws. Torque setting to
be 21-30 in-lbs (2.4-3.4 N-m). Insert the inlet Tubing
into Seal Assembly.
7. Install the two Mufers, O-Ring, Captive Ring, O-Ring
into the End Cap. Lightly grease the o-rings before
installation.
8. Coat the threads of the Bushing Assembly with 1 or 2
drops of Loctite™ 222 or equivalent non-permanent
pipe thread sealant. Screw the Bushing Assembly into
the inlet port on the End Cap until hand tight. Torque
setting to be 60-72 in-lb (6.8-8.1 N-m).
9a. For CV and SGV machines: Insert the Inlet Tubing into
the End Cap. Install the Inlet Tubing into the Seal As-
sembly.
9b. For NV machines: Insert the inlet Tubing into the End
Cap.
10. Install the Mufer and Seals into the Housing.
11. Install the internal components into the Housing. Then
install the Housing.
12. Install the Screws. Torque setting to be 27- 30 in-lbs
(3.0-3.4 N-m) for Screw. Torque setting to be 29- 33
in-lbs (3.3-3.7 N-m) for Screw.
13. Lightly grease the O-Ring and place it in the groove on
the Speed Control. Insert the Speed Control into the
Motor Housing in the full on position. Install the Retain-
ing Ring. Caution: Make sure the Retaining Ring is
completely snapped into groove in the Motor Housing.
14. Install the Spacer Ring into the Hanger. Secure the
hanger by screwing in the Plugs and/or install the Side
Handle.
Spindle, AirSHIELD™ and Shaft Balancer Assembly:
1. Place the T-1A Spindle Bearing Pressing Tool Base
onto a at, clean surface of a small hand press or
equivalent with the pocket facing upward. Place the
Spindle into the spindle pocket with the shaft facing
upward.
2. Place the Washer on the Spindle shaft with the curve
of the Washer facing up so that the outside diameter
of the Washer will contact the outer diameter of the
Bearing. Place the Dust Shield onto the Spindle shaft.
Place the Spacer onto the shoulder of the Spindle.
Note: Be sure that the Dust Shield is past the shoulder
where Spacer rests. Place the Bearing on the Spindle
with the seal side toward the Washer. Note: Make sure
that both the inner and outer races of the Bearing are
supported by the Bearing Press Tool when pressing
them into place. Press the Bearing to the Spacer using
the T-1B Spindle Bearing Pressing Tool Top.
3. Take the Filter and center it on the small bore that the
original Filter was in before removal. With a small
diameter screwdriver or at-ended rod, press the Filter
into the bore until it is at in the bottom of the bore.
Place the Valve into the bore so it is oriented correctly,
then press the Retainer into the bore until it is ush with
the surface of the Shaft Balancer.
4. Apply a pin head size drop of #271 Loctite® or
equivalent to the outside diameter of the Bearing of
the Spindle Assembly. Spread the drop of bearing
locker around the Bearings until it is distributed evenly.
Caution: Only a very small amount of bearing locker
is needed to prevent rotation of the bearing OD. Any
excess will make future removal difcult. Place the
Spindle Assembly 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 Balancer shaft. Allow the adhesive to
cure.
Motor Assembly:
1. Place the Dust Shield onto the shaft of the Shaft Bal-
ancer.
2. Lightly grease the O-Ring with a light mineral grease
and place it in the groove of the Lock Ring, then place
it on the Shaft Balancer with the O-Ring facing towards
the keyway.
3. 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.
4. Slide the Front Endplate with the bearing pocket facing
down onto the motor shaft. Gently press the Front
Endplate onto the 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.
Caution: Only press just enough to seat the Bearing
into the pocket. Over-pressing can damage the Bear-
ing.
5. Place the two Keys into the grooves of the Shaft
Balancer. Place the Rotor onto the shaft of the Shaft
Balancer, making sure that it is a light slip t.
6. Place the Cylinder Assembly 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 anged side of the Cylin-
der. Oil the ve Vanes with a quality pneumatic tool oil
and place in the slots in the Rotor. One or two drops of
oil should be sufcient.
7. Press t the rear Bearing (2 shields) into the Rear
Endplate with the T-1B Bearing Press Tool. Make sure
the T-1B Press Tool is centered on the O.D. of the

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
8
Clayton™ Back-Up Pads
Clayton back-up pads are perfectly mated for use on the
Clayton ROS. Constructed from premium, industrial-quality
materials and featuring a riveted berglass and steel hub
with molded urethane, their durability and precise construc-
tion are the ideal complement to the performance of the
Clayton ROS.
outer race of the Bearing. Lightly press t the Rear
Endplate and Bearing 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 Endplate and Bearing 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 motor assembly 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 Motor
Housing.
8. Secure the assembly by placing the Retaining Ring in
the groove of the Shaft Balancer. Caution: The Retain-
ing Ring must be placed so that the middle and two
ends of the hoop touch the Bearing rst. Both raised
center portions must be securely “snapped” into the
groove in the Shaft Balancer by pushing on the curved
portions with a small screwdriver.
9. Lightly grease the O-Ring and place in the air inlet of
the Cylinder Assembly.
10. Lightly grease or oil the inside diameter of the Motor
Housing, line up the spring pin of the Cylinder Assem-
bly with the marking on the Motor Housing and slide
the Motor Assembly into the Motor Housing. Make
sure the Spring Pin engages the pocket in the Motor
Housing. Carefully screw the Lock Ring into the Motor
Housing with the T-6 Motor Lock Ring Wrench/Spindle
Puller Tool. Torque settings to be 55-65 in-lb (6.2-7.3
N-m). Note: A simple technique to assure rst thread
engagement is to turn the Lock Ring counter-clockwise
with the T-6 Motor Lock Ring Wrench/Spindle Puller
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.
11. Spin on a new Pad and hand-tighten it using the Pad
Wrench.
Testing:
Place 3 drops of quality pneumatic air tool oil directly into
the motor inlet and connect the machine to a 90-psig (6.2
bar) air supply. A 12,000 RPM tool should run between
11,500 to 12,500 RPM 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 be-
cause of wind resistance. This will not affect performance
when sanding.
* Loctite® is a registered trademark of the Loctite Corp.
General Specications
Size 5”
3/16 orbit
5”
3/8 orbit
6”
3/16 orbit
6”
3/8 orbit
Sound Level
(EN ISO 15744:2008) * 84dBA *83 dBA *85 dBA *81 dBA
Power .46 hp .46 hp .46 hp .46 hp
Speed RPM 12,000 12,000 12,000 12,000
Vibration
(EN ISO 8662-8:1997;
EN ISO 28662-1:1992)
*3.2 m/s2*3.5 m/s2* 3.0m/s2*3.4 m/s2
*Uncertainty 1.6 K m/s21.8 K m/s21.5 K m/s21.7 K m/s2
Specications subject to change without prior notice.
*The values stated in the table are from laboratory testing
in conformity with stated codes and standards and are not
sufcient for risk evaluation. Values measured in a par-
ticular 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 expo-
sure 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.
Further occupational health and safety information can be
obtained from the following websites:
http://europe.osha.eu.int (Europe)
http://www.osha.gov (USA)
Specications
Description Part #
Clayton 5” tapered edge, vac, vinyl face 672-511S
Clayton 5” low prole, screen vac, j-hook face 672-511J
Clayton 6” tapered edge, vac, vinyl face 672-611S
Clayton 6” low prole, screen vac, j-hook face 672-611J
Clayton 5“ Protector Pads 672-50JP
Clayton 6“ Protector Pads 672-60JP
Clayton 5“ Interface Pads 672-52JP
Clayton 6“ Interface Pads 672-62JP

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
9
Symptom Possible Cause Solution
Low Power and/or Low Free Speed
Insufcient Air Pressure
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).
Clogged Mufer(s)
See the “Housing Disassembly” section
for Mufer removal. The Mufer can
be back ushed with a clean, suitable
cleaning solution until all contaminates
and obstructions have been removed. If
the Mufer can not be properly cleaned
then replace it. Replace Mufer Insert
(See the
“Housing Assembly” Section).
Plugged Inlet Screen
Clean the Inlet Screen with a clean,
suitable 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,
AirSHIELD™ and Shaft Balancer As-
sembly”.
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
designed for the machine.
Addition of interface pad or other material
Only use abrasive and/or interface
designed for the machine. Do not at-
tach anything to the Sanders Pad face
that was not specically designed to be
used 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.
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 at surface causing the pad to stick to
the 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
DOC 2152 Rev 11/24/16

Copyright © 2016 Clayton Associates, Inc. • 1650 Oak St. • Lakewood, NJ 08701
800-248-8650 • www.VacuumSanding.com
10