Clarke CAT 220, 3110474 User guide

3” ANGLE POLISHER

MODEL NO: CAT220

PART NO: 3110474

OPERATING & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC 0422

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

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

Uncertainty Factor

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.

3”/75mm

7.77 m/s

1.5 m/s

2

2

2

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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 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.

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 condition 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.

3

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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 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
for 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 airbourne particles. Avoid
disturbing existing dust and minimise the scattering of dust in the worplace
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 0

4

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

o

C.

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

5

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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 air line 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.

6

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

• 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 metres), 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.

7

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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 P AD OR MOP

1. Select your attachment (either lambswool mop or sponge pad). Line up
and centre 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.

8

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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 lig h t pres s ure wh i le moving the polisher across the
su r f a ce i n sweeping strokes, creating a cris-cross pattern. Apply any
polishing wax evenly.

6. Increase the air flow 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 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 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.

9

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

• 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, air line 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.

10

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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 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.

**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 metres) etc. Contact your CLARKE dealer for

further information or CLARKE International Service Department.

11

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

TROUBLESHOOTING

SYMPTOM PROBLEM SOLUTION

Tool runs at normal
speed but slows down
under any load.

Tool runs slowly. Air flows
weakly from exhaust.

Tool will not run. Air flows
freely from exhaust.

Loss of power or erratic
performance.

Tool will not shut off. 1. Throttle O-rings

1. Excessive pressure on
tool.

2. Motor parts worn.

3. Worn or sticking
mechanism due to
lack of lubricant.

1. Motor parts jammed
with gum/dirt.

2. Regulator in closed
position.

3. General airflow
blocked by dirt.

1. Motor vanes stuck
due to buildup of
foreign material.

1. Excess demand on
air supply. Wrong size
or type of inlet
connectors.

2. Moisture or other
restriction in airline

3. Compressor supplies
insufficient air.

4. Air hose leaks.

damaged or ill-fitting
in seat.

1. Reduce the force
applied to the tool.

2. Return to your CLARKE
dealer for repair.

3. Drip air tool lubricating
oil into air inlet. Allow oil
to soak moving parts
before using.

1. Examine inlet air filter for
cleanliness.

2. Adjust regulator to open
position.

3. Operate tool in short
bursts.

1. Disconnect air supply
and rotate tool assembly
manually.

2. Try operating tool in
short bursts.

3. Drip a few drops of air
tool lubricating oil into air
inlet to soak moving parts

1. Isolate other air tools in
use. Check air hose and
confirm correct fittings.

2. Vent system and ensure
air reservoir and airline
are free of water.
Insert oil into tool and run
briefly. Confirm no water
is expelled.

3. Ensure flow rate is
adequate for the size of
air tool.

4. Tighten and seal fittings.

1. Return to your CLARKE
dealer for repair.

12

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

DECLARATIONS OF CONFORMITY

13

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

PART S LIS T

No Description No Description

1 Main housing 19 Eccentric wheel

2 Bush 20 Screw

3 Valve pin 21 Grub screw

4 Spring 22 Drive spindle

5O-ring 23Bearing

6 Screw cap 24 Circlip

7 Trigger pin 25 Backing disc

8 Trigger 26 O-ring

9 Bearing 27 Muffler stand

10 Front plate 28 O-ring

11 Cylinder 29 Muffler liner

12 Pin 30 Muffler

13 Rotor 31 Grub screw

14 Rotor blade 32 Air regulator

15 Rear plate 33 Soft grip

16 Bearing 34 Spindle locking pin

17 O-ring 35 O-ring

18 Top cover 36 O-ring

14

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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 effect your statutory rights.

15

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]