Clarke CAT220 3 Inch Angle Polisher Instruction Manual

3” ANGLE POLISHER
MODEL NO: CAT220
PART NO: 3110474

OPERATING & MAINTENANCE INSTRUCTIONS 

ORIGINAL INSTRUCTIONS
GC0422

INTRODUCTION

Thank you for purchasing this CLARKE Air Polisher. The foam applicator and buffing pads with hook and loop attachment make changing between items quick and easy.
Before attempting to use this product, please read this manual thoroughly and follow the instructions carefully. In doing so you will ensure the safety of yourself and that of others around you, and you can look forward to your purchase giving you long and satisfactory service.

SPECIFICATION

Model Number|

CAT220

---|---
Dimensions (L x W x H)| 170 x 45 x 90 mm
Backing Pad/Foam Pad/Wool Bonnet Diameter| 3”/75mm
Weight| 0.8 kg
Pad size| 3” (75mm)
Air Inlet Size| 1/4“BSP (female)
Operating Pressure| 90 psi (6.2 bar)
Air Consumption| 5.75 cfm average
No Load Speed| 15000 rpm @ 90psi
Sound Pressure Level (LpA dB)| 85 dB(A)
Sound Power Level (LwA dB)| 96 dB(A)
Uncertainty Factor (K)| 3
Vibration Levels| 7.77 m/s2
Uncertainty Factor| 1.5 m/s2

Please note that the details and specifications contained herein are correct at the time of going to print. However CLARKE International reserves the right to change specifications at any time without prior notice.

GENERAL SAFETY RULES

CAUTION: FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY, AND/OR DAMAGE TO PROPERTY.

WORK ENVIRONMENT

1. Keep the work area clean and tidy.
2. Dress appropriately – DO NOT wear loose clothing or jewelry. 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.

PERSONAL SAFETY

1. Stay alert and use common sense – DO NOT operate the air tool when you are tired or under the influence of alcohol, drugs or medication.
2. ALWAYS wear eye protection when using the tool – This must provide protection from flying particles from the front and the side.
3. ALWAYS wear ear protection when using the air tool.
4. ALWAYS wear a dust mask when operating this type of tool.
5. DO NOT overreach – Keep proper footing and balance at all times.

USE OF AIR-POWERED TOOLS

1. NEVER use oxygen, CO², combustible gases, or any type of bottled gas as a source of power for the tool.

2. DO NOT connect the air supply hose with your finger on the trigger.

3. DO NOT exceed the maximum pressure for the tool of 90 psi / 6.2 bar.

4. Check hoses for leaks or worn conditions before use, and ensure that all connections are secure.

5. DO NOT use the tool for any other purpose than described in this manual.

6. Keep the air supply hose away from heat, oil and sharp edges.

7. DO NOT fit the tool to any stand or clamping device that may damage it.

8. The tool should be serviced at regular intervals by qualified service personnel.

9. DO NOT carry out any alterations or modifications to the tool.

10. NEVER use the tool if it is defective or operating abnormally.

11. ALWAYS disconnect from the air supply when:
    • Performing any maintenance.
    • The tool is not in use.
    • The tool will be left unattended.
    • Moving to another work area.
    • Passing the tool to another person.

12. Avoid damaging the tool by applying an excessive force of any kind.

13. ALWAYS maintain the tool with care. Keep it clean for the best and safest performance.

14. Quick change couplings should not be located at the tool. They add weight and could fail due to vibration.

15. DO NOT force or misuse the tool. It will do a better and safer job at the rate at which it was designed.

16. 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.

USE OF THE POLISHING TOOL

1. Try to hold the tool with both hands. Ensure that the workpiece is kept at waist height where possible. NEVER use the tool between the legs whilst sitting on the floor.
2. ALWAYS allow the tool to run up to full operating speed before applying it to the job.
3. Use clamps, or vices to hold a loose workpiece. Failure to secure the workpiece could result in personal injury.
4. Inspect the pad/mop before use. DO NOT use if split or torn.
5. ALWAYS wear a face mask as protection from airborne particles. Avoid disturbing existing dust and minimize the scattering of dust in the workplace environment. Take steps to control the dust at the point of emission.

TRANSPORTATION AND STORAGE

1. NEVER carry the tool by the air supply hose.
2. NEVER carry the tool with your finger on the trigger.
3. 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.
4. Avoid storing the tool in environments where the temperature is below 0ºC.

OVERVIEW

NO| DESCRIPTION| NO|

DESCRIPTION

---|---|---|---
1| Spindle access port| 6| Spindle Locking pin
2| Trigger| 7| Foam applicator pads (coarse/fine)
3| Speed Regulator| 8| Backing disc
4| Air Inlet (with travel plug)| 9| Wool buffing mop
5| Air exhaust| |

COMPRESSED AIR REQUIREMENTS

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR COMPRESSORS AND COMPRESSED AIR SUPPLIES.

• A typical airline layout is shown below. 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.

AIR SYSTEM LAYOUT :

1. Air Tool
2. Air Hose 3/8″ (I.D.)
3. Oiler
4. Pressure Regulator
5. Filter
6. Shut Off Valve
7. Whip Hose
8. Coupler Body And Connector
9. Drain Daily
10. 1/2″ Or Larger Pipe And Fitting
11. Air Dryer
12. 1″ Or Larger Pipe And Fitting
13. Air Compressor
14. Auto Drain
15. Drain Daily

• The air hose must be rated at least 150% of the maximum operating pressure of the tool
• 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 meters), the line pressure or the hose inside diameter may need to be increased.
• NEVER exceed the maximum operating pressure for the tool. It is recommended that air pressure to this tool does not exceed 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.

BEFORE USE

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF AIR COMPRESSORS AND COMPRESSED AIR SUPPLIES.

NOTE: Ensure the compressor is turned off and remove the travel plug from the inlet connection of the air tool.

1. If required, connect an in-line mini oiler to the tool.
   • A mini oiler helps to prolong the life of the air tool.

2. Connect a suitable hose with a male connector to the air inlet as shown by screwing it in as shown.

3. Connect the other end of the hose to the compressor.

4. Run the compressor at low pressure and check for leaks.

5. If a mini-oiler is not being used, run a few drops of oil through the tool before use. It can be entered through the air inlet or via the hose at the nearest connection to the air supply.

You can fit a whip hose with a quick fit coupling if required (available from your CLARKE dealer).

FITTING THE BACKING DISC
Insert the spindle locking pin through the aperture provided and into the hole in the drive spindle to stop the spindle from rotating. Thread the backing disc into the drive spindle by turning it clockwise. Tighten the disc using the locking pin provided to prevent the drive shaft from rotating.

ATTACHING THE PAD OR MOP

1. Select your attachment (either lambswool mop or sponge pad). Line up and center your choice of attachment to the backing disc.
2. Press either the sponge pad or mop against the backing disc so that the hook and eye surfaces engage. Run your hand over the surface to ensure it is affixed.

OPERATION

RUNNING THE TOOL
The polisher should run at a suitable speed which can be regulated as required by turning the regulator.

• The regulator turns through 90 degrees between fully on and fully off.

1. Squeeze the trigger against the body of the tool to run.

2. Release the trigger to stop the tool.
   • The tool will continue to rotate very briefly after the trigger has been released.

3. ALWAYS ensure the tool has stopped before putting it down.

USING THE POLISHER
IMPORTANT: Do not add too much wax to the applicator pad, as it will increase the time and effort needed to complete the task. A saturated pad may also separate from the disc pad during use.

1. Clean the workpiece’s surface to remove dust, dirt, oil, or grease.

2. Place a clean foam applicator pad securely onto the backing disc.

3. Apply a smear of wax polish (not included) evenly on the clean foam applicator pad. The pad will absorb some of the wax.

4. Place the polishing pad on the workpiece and squeeze the trigger.
   • The speed is controlled by adjusting the air regulator.

5. DO NOT apply pressure to the polisher until it reaches full speed. Apply light pressure while moving the polisher across the surface in sweeping strokes, creating a criss-cross pattern. Apply any polishing wax evenly.

6. Increase the airflow if more power is needed to accomplish the task. DO NOT exceed the maximum airflow or PSI (see Specifications).
   • A larger tool may be required if the tool still does not have sufficient force at maximum pressure and sufficient airflow.

7. Add additional wax to the pad as needed. Release the trigger and allow the polisher to come to a complete stop, add a small amount of wax and resume operation.

8. After the wax has been applied to the vehicle’s surface, release the trigger and disconnect the air supply.

9. Allow sufficient time for the wax to dry.

10. Place a clean wool buffing pad securely onto the disc.

11. Start the polisher and begin buffing off the dried wax.

12. When you have removed as much wax as you can with the polisher. release the trigger and disconnect the air supply.

13. Remove the buffing pad from the backing disc. Using the buffing pad, remove the wax from all hard-to-reach areas of the vehicle.

14. To prevent accidents, release the trigger, detach the polisher from the air supply and safely discharge any residual air pressure in the tool.
    POLISHING TIPS
    • DO NOT use excess pressure on the pad as this will shorten its life.
    • Allow the pad to reach working speed before polishing.
    • Avoid overloading the polisher. If it becomes hot during use, rest for a few minutes while it cools down.

DISCONNECTING THE AIR SUPPLY

1. DO NOT disconnect the air supply hose until the compressor has been shut down and the compressed air released.
2. 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 tool.

MAINTENANCE

WARNING: MAKE SURE THAT THE AIR TOOL IS DISCONNECTED FROM THE AIR SUPPLY BEFORE STARTING ANY CLEANING OR MAINTENANCE PROCEDURES.

DAILY

1. Before use, drain water from the air tank, airline, and compressor.
2. Pour a few drops of CLARKE airline oil into the air inlet. This should be carried out regardless of whether or not an in-line mini oiler is used. If an in-line mini oiler is not used, this procedure should be repeated after every two to three hours of use.

CLEANING

1. Wash the mop after each use by hand and use mild soap with water. Hang it up to dry.
   • Store flat and allow it to regain shape.

2. Check the air inlet strainer for blockage and clean if necessary.

3. Keep the body of the tool clean and free from debris.

4. Grit or gum deposits inside the tool may also reduce its efficiency. This condition can be corrected by cleaning out the air strainer and flushing out the tool with gum solvent or oil, or failing this, the motor may require dismantling. This is better left to your CLARKE dealer.

SERVICE AND REPAIR
If the tool runs erratically or becomes inefficient although the air supply is in good order, it may be necessary to dismantle the air motor and replace any worn or damaged parts. Such servicing and repair work should be carried out by a qualified service technician.
PERFORMANCE
Please note that factors other than the tool may affect 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. CLARKE Air Line Oil (part no. 3050825) is available from your CLARKE dealer.
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 run the tool for 5 seconds in order to lubricate the internal parts.
When not in use, disconnect from the air supply, clean tools, and store, ensuring the blanking plug is replaced on the airline connector when the airline is disconnected.
ACCESSORIES**
A wide range of accessories is available including filter/regulators, lubricators, high-pressure hoses (5 to 50 meters), etc. Contact your CLARKE dealer for further information or CLARKE International Service Department.

TROUBLESHOOTING

SYMPTOM| PROBLEM|

SOLUTION

---|---|---
Tool runs at normal speed but slows down under any load.| 1.  Excessive pressure on the tool.
2.  Motor parts are worn.| 1.  Reduce the force applied to the tool.
2.  Return to your CLARKE dealer for repair.
3.  Drip air tool lubricating oil into the air inlet. Allow the oil to soak moving parts before using.
| 3. Worn or sticking mechanism due to lack of lubricant.
Tool runs slowly. Air flows weakly from the exhaust.| 1.  Motor parts jammed with gum/dirt.
2.  Regulator in the closed position.
3.  General airflow blocked by dirt.| 1.  Examine the inlet air filter for cleanliness.
2.  Adjust the regulator to an 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 the tool in short bursts.
3.  Drip a few drops of air tool lubricating oil into air inlet to soak moving parts
Loss of power or erratic performance.| 1.  Excess demand on the air supply. Wrong size or type of inlet connectors.
2.  Moisture or other restriction in airline| 1.  Isolate other air tools in use. Check the air hose and confirm the correct fittings.
2.  Vent system and ensure air reservoir and airline are free of water.
Insert oil into the tool and run briefly. Confirm no water is expelled.
3.  Ensure the flow rate is adequate for the size of the air tool.
4.  Tighten and seal fittings.
| **** 3. Compressor supplies insufficient air.
| 4. Air hose leaks.
Tool will not shut off.| 1. Throttle O-rings damaged or ill-fitting in the seat.| 1. Return to your CLARKE dealer for repair.

DECLARATIONS OF CONFORMITY

Clarke®
INTERNATIONAL
Homnall Street. Epping. Essox CM16 4LG
DECLARATION OF CONFORMITY This is an important document and should be retained.
We hereby declare that this product(s) complies with the following statuary requirement(s): Supply of Machinery (Safety) Regulations 2008
The following standards have been applied to the product(s): EN ISO 11148-4:2012
The technical documentation required to demonstrate that the product(s) meet(s) the requirement(s) of the aforementioned legislation has been compiled and is available for inspection by the relevant enforcement authorities.
The UKCA mark was first applied in 2022
Product Description: NW Air Punch and Flange Tool
Model number(s): CAT216
Serial/batch Number: N/A
Date of Issue: 30/03/2022
Signed:

INTERNATIONAL
Fitzwilliam Half: Fitzwilliam Place, Dublin 2
DECLARATION OF CONFORMITY This is an important document and should be retained.
We hereby declare that this product(s) complies with the following directive(s): 2006/42/EC Machinery Directive
The following standards have been applied to the product(s): EN ISO 114&4:2012
The technical documentation required to demonstrate that the product(s) meet(s) the requirement(s) of the aforementioned directive(s) has been completed and is available for inspection by the relevant enforcement authorities.
The CE mark was first applied in: 2022
Product Description: 3/16″ Air Punch and Flange Tool
Model number(s): CAT216
Serial I batch Number N/A
Date of Issue: 30/032022

Signed:

CAT2 I 6 CE Clarke DOC 033022

PARTS LIST

PARTS DIAGRAM

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 affect your statutory rights.

A SELECTION FROM THE VAST RANGE OF

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From DIY to industrial, Plus air tools, spray guns and accessories.
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All sizes for car and commercial use.

|

PARTS & SERVICE: 0208 988 7400
Parts Enquiries
Parts@clarkeinternational.com
Servicing & Technical Enquiries
Service@clarkeinternational.com
SALES: UK 01992 565333 or Export 00 44 (0)1992 565335
Clarke® INTERNATIONAL Hemnall Street, Epping, Essex CM16 4LG
www.clarkeinternational.com
Parts & Service: 020 8988 7400 
E-mail: Parts@clarkeinternational.com
Service@clarkeinternational.com 

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