Clarke CP 180, 6462105 User guide

OPERATION & MAINTENANCE

INSTRUCTIONS

SANDER/POLISHER

SANDER/POLISHER

MODEL NO: CP180

PART No: 6462105

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Thank you for purchasing this CLARKE Sander/Polisher, which is designed for DIY use.

Before attempting to use the machine, 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 the product giving you long and
satisfactory service.

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.

Specifications

Elec. Supply ................................................. 230V 50Hz 1 ph

Power Rating .............................................. 1300W Motor

Fuse Rating .................................................. 13amp

No Load Speed .......................................... 1,000-3,000 RPM

Sound Power Level .................................... 98.1dB(A)

Net Weight .................................................. 5.0 kg

Spindle Thread ........................................... M14

Vibration
Measured vibration emission value -

Highest reading in a single plane ............... 5.1m/s

Values determined according to EN28622-1

a: .

<2.5m/s

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Residual Risks

Even when the power tool is used as prescribed it is not possible to eliminate all
residual risk factors. The following hazards may arise in connection with the power
tool’s construction and design:

1. Damage to lungs if an effective dust mask is not worn.

2. Damage to hearing if effective hearing protection is not worn.

3. Damages to health resulting from vibration emission

if the power tool is being used over longer period of time or not adequately
managed and properly maintained.

WARNING! This machine produces an electromagnetic field during operation. This
field may under some circumstances interfere with active or passive medical
implants. To reduce the risk of serious or fatal injury, we recommend persons with
medical implants to consult their physician and the medical implants manufacturer
before operating this machine.

Environmental Protection

Do not dispose of this product with general household waste. All tools,
acessories and packaging should be sorted, taken to a re-cycling centre
and disposed of according to the laws governing Waste Electrical and
Electronic Equipment.

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Safety Precautions

WARNING:

As with all machinery, there are certain hazards involved with their operation

and use. Exercising respect and caution will considerably lessen the risk of

personal injury. However, if normal safety precautions are overlooked or

ignored, personal injury to the operator or damage to property, may result.

1. ALWAYS Learn the machine’s applications, limitations and the
specific potential hazards peculiar to it. Read and become familiar
with the entire operating manual.

2. ALWAY S use a face or dust mask if operation is particularly dusty.

3. ALWAYS check for damage. Before using the machine, any
damaged part, should be checked to ensure that it will operate
properly, and perform its intended function. Check for alignment of
moving parts, breakage of parts, mountings, and any other condition that may
affect the machines’ operation. Any damage should be properly repaired or the
part replaced. If in doubt, DO NOT use the machine. Consult your local dealer.

4. ALWAYS disconnect the tool/machine from the power supply before servicing and
when changing accessories.

5. ALWAYS wear safety goggles, manufactured to the latest European Safety Standards.
Everyday eyeglasses do not have impact resistant lenses; they are not safety glasses.

6. ALWAYS keep work area clean. Cluttered areas and
benches invite accidents.

7. ALWAYS ensure that adequate lighting is available. A
minimum intensity of 300 lux should be provided. Ensure
that lighting is placed so that you will not be working in your
own shadow.

8. ALWAY S keep children away. All visitors should be kept a safe
distance from the work area, especially whilst operating the
machine.

9. ALWAYS maintain machine in top condition. Keep tools/machines
clean for the best and safest performance. Follow maintenance
instructions.

10. ALWAYS handle with extreme care. Do not carry the tool/machine by its’ electric
cable or yank the cable to disconnect it from the power supply.

11. ALWAYS ensure the switch is off before plugging in to
mains. Avoid accidental starting.

12. A LWAYS concentrate on the job in hand, no matter how
trivial it may seem. Be aware that accidents are caused
by carelessness due to familiarity.

13. ALWAYS keep your proper footing and balance at all
times - don’t overreach. For best footing, wear rubber soled footwear. Keep floor
clear of oil, scrap wood, etc.

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Electrical Connections

Connect the mains lead to a standard 230V (50Hz) electrical supply through an approved
13 Amp BS1363 plug or a suitably fused isolator switch.

WARNING: This appliance is DOUBLE INSULATED

IMPORTANT:

The wires in the mains lead are coloured in accordance with

the following code:

Blue - Neutral

Brown - Live

As the colours of the flexible cord of this appliance may not correspond with the coloured
markings identifying terminals in your plug proceed as follows:

• Connect BROWN coloured cord to plug terminal marked with a letter L or

• Connect BLUE coloured cord to plug terminal marked with a letter N or coloured

IMPORTANT:

If this appliance is fitted with a plug which is moulded on to

coloured RED.

BLACK.

the electric cable (i.e. non- re-wireable) please note:

1. The plug must be thrown away if it is cut from the
electric cable. There is a danger of electric shock if
it is subsequently inserted into a socket outlet.

2. Never use the plug without the fuse cover fitted.

3. Should you wish to replace a detachable fuse
carrier, ensure that the correct replacement is used
(as indicated by marking or colour code).

4. Replacement fuse covers can be obtained from
your local dealer or most electrical stockists.

5. The fuse in the plug must be replaced with one of the same rating (13 amps) and this
replacement must be approved to BS1362.

IMPORTANT: If in any doubt, do not attempt any electrical repair yourself.
Consult a qualified technician.

IMPORTANT:

If a cable extension is needed, it is essential to comply with the following data.

Voltage Extension length Cable section

230v Up to 20m 2.5mm
230v From 20 to 50m 4mm

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2

2

Overview

‘D’ Handle

Speed Control

Trigger Lock

Spindle Lock

Motor Brush

Side Handle

Backing Pad

Polishing Hood

Fig. 1

Trigger

Assembly

Before assembling the sander/polisher, check for missing
parts and or damage caused in transit. Any defects
must be reported to the Clarke dealer where the tool
was originally purchased as soon as possible.

IMPORTANT: Before carrying out any adjustments or
repairs, ensure the sander/polisher is isolated from the
main electric supply by switching off and
removing the plug from the socket.

Fitting Handles

The handles can be fitted for either left or
right handed use, it is also possible to fit one or
both handles, depending on individual
choice.

1 ‘D’ Handle Only

Slot the ‘D’ handle onto the body of the tool
see Fig. 2.

NOTE: the handle is recessed to fit onto the tool in one position only, and is not adjustable,
other than for left or right handed use.

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D Shaped Boss

Fig. 2

When the handle is in place, secure it in position
with two allen screws and tighten the screws
using an 8mm Allen key. DO NOT overtighten.

2 Side Handle Only

To use the side handle only, screw into the D
shaped boss on either side of the body,
depending whether the tool is to be used left or
right handed. See Fig. 3. DO NOT overtighten.

3 Both Handles

To fit both handles, Fit the ‘D’ Handle as
described in section 1.

Only fit one Allen screw to the longest side of the handle as shown in Fig. 4, DO NOT
tighten yet.

Secure the other side using the side
handle, hand tight only, tighten the Allen
screw as before.

NOTE: store the spare Allen
screw for use to secure the ‘D’
handle should it be necessary
to remove the side handle.

Fitting Backing Pads

To fit backing pads, depress the spindle
lock and screw the required backing
pad onto the spindle, hand tight only.

To remove the pads it may be necessary to use the spanner supplied.

IMPORTANT never depress the spindle lock whilst the motor is running. Failure to observe
this instruction may cause damage to the tool and could even lead to personal injury.

Depending on which pad is fitted, either the polishing bonnet or sanding discs can be
fitted.

When fitting the bonnet ensure the lace tails are tucked away before switching the
polisher on.

Allen Screw

Fig. 3

Fig. 4

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Operation

When using this tool, always hold it firmly with both hands. Before switching the tool on,
always check for damage/missing parts etc. Any defects must be rectified before
continuing.

Whether polishing or sanding, always ensure the workpiece is securely fixed, i.e. clamped
to workbench or secured in a vice.

When working on car bodywork, always ensure that there is no possibility of loose items
being left on the car bonnet, boot or roof. The vibration may cause the items to fall onto
the rotating disc and be thrown, leading to injury to those in the work vicinity. Always
keep the work area tidy.

Firmly hold the sander/polisher with both hands and switch the tool ON. To do this, fully
depress the trigger lock button (Fig 1), whilst holding the button in fully, depress the trigger,
and the motor will start.

NOTE: the motor will start slowly and gradually increase to full speed. This is a safety
feature known as soft start which gives smooth control on startup.

As soon as the motor has reached full speed, adjust the speed control to the desired
working speed.

Slowly apply the rotating disc to the workpiece and proceed to sand or polish, moving
the disc across the work applying a light even pressure. DO NOT attempt to force the tool
as this will cause an uneven finish and may even lead to premature motor failure.

If it is necessary to change the speed, always lift the disc from the work surface, adjust the
speed control to the required speed, then reapply to the work surface and continue as
before.

On completion, lift the disc from the work surface before releasing the trigger, ensuring the
motor has come to a complete stop before setting the tool down on the workbench etc.
Failure to do so can cause the tool to be thrown, resulting in damage to the tool or serious
personal injury.

Maintenance

Inspect the sander/polisher regularly for signs of wear or damage, any defects should be
rectified before using the tool again.

All the bearings used in this product are sealed and lubricated with a sufficient quantity of
high grade lubricant, which should under normal operating conditions, last the lifetime of
the tool.

Regularly clean the tool, using a clean soft brush and/or clean soft cloth. DO NOT use any
abrasive cleaning agents on any part of the tool.

Most plastics are susceptible to various solvents and cleaning agents, and may be damaged
if allowed to come into contact with them, e.g. brake fluids and petroleum based products
etc.

Occasionally remove and inspect the motor brushes and replace if necessary. When
removing brushes, note which way round they are etc. The brushes must be returned
exactly as they are removed. DO NOT swop over positions etc.

Never allow the brushes to wear more than two thirds of their original length, new brushes
are approximately 13mm long. Fit new brushes when they are worn down to 5mm.

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HAND-ARM VIBRATION

Employers are advised to refer to the HSE publication “Guide for Employers”.

All hand held power tools vibrate to some extent, and this vibration is transmitted to the operator
via the handle, or hand used to steady the tool. Vibration from about 2 to 1500 Herz is potentially
damaging and is most hazardous in the range from about 5 to 20 Herz.

Operators who are regularly exposed to vibration may suffer from Hand Arm Vibration Syndrome
(HA VS), which includes ‘dead hand’, ‘dead finger’, and ‘white finger’. These are painful conditions
and are widespread in industries where vibrating tools are used.

The health risk depends upon the vibration level and the length of time of exposure to it……in
effect, a daily vibration dose.

Tools are tested using specialised equipment, to approximate the vibration level generated under
normal, acceptable operating conditions for the tool in question. For example, a grinder used at
45° on mild steel plate, or a sander on softwood in a horizontal plane etc.

These tests produce a value‘a’, expressed in metres per second per second, which represents the
average vibration level of all tests taken, in three axes where necessary, and a second figure ‘K’,
which represents the uncertainty factor, i.e. a value in excess of ‘a’, to which the tool could
vibrate under normal conditions. These values appear in the declaration on page 2.

You will note that a third value is given in the specification - the highest measured reading in a
single plane. This is the maximum level of vibration measured during testing in one of the axes,
and this should also be taken into account when making a risk assessment.

‘a’ values in excess of 2.5 m/s2 are considered hazardous when used for prolonged periods. A tool
with a vibration value of 2.8 m/s2 may be used for up to 8 hours (cumulative) per day, whereas a
tool with a value of 11.2 m/s2 may be used for ½ hour per day only.

The graph below shows the vibration value against the maximum time the respective tool may be
used, per day.

The uncertainty factor should also be taken into account when assessing a risk. The two figures
‘a’ and ‘K’may be added together and the resultant value used to assess the risk.

It should be noted that if a tool is used under abnormal, or unusual conditions, then the vibration
level could possibly increase significantly. Users must always take this into account and make

their own risk assessment, using the
graph as a reference.

Some tools with a high vibration value,
such as impact wrenches, are
generally used for a few seconds at a
time, therefore the cumulative time
may only be in the order of a few
minutes per day. Nevertheless, the
cumulative effect, particularly when
added to that of other hand held
power tools that may be used, must
always be taken into account when
the total daily dose rate is
determined.

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Parts List

Item Part No Description Qty

1 HT18001 Spindle 1
2 HT18002 Key 4 x 5 x 13 1
3 HT18003 Screw M5 x 16 4
4 HT18004 Spring Washer Ø5 4
5 HT18005 Gear Housing Cover 1
6 HT18006 Bearing 6002.RS 1
7 HT18007 Bearing Cover 1
8 HT18008 Spring Washer Ø4 6

9 HT18009 Screw M4 x 10 6
10 HT18010 Large Gear 1
11 HT18011 Wave Spring Washer 1
12 HT18012 Circlip for Shaft Ø14 1
13 HT18013 Bronze Bush 1
14 HT18014 Gear Housing 1
15 HT18015 Screw ST5x45 4
16 HT18016 ‘E’ Ring Ø6 1
17 HT18017 Break Spring 1
18 HT18018 Break Pin 1
19 HT18019 Rubber Plunger 3
20 HT18020 Side Handle 1
21 HT18021 Circlip for shaft Ø12 1
22 HT18022 Bearing 6201.RS 1
23 HT18023 Bearing Cover 1
24 HT18024 Armature 1
25 HT18025 Bearing 608.2z 1
26 HT18026 Bearing Bushing 1
27 HT18027 Guide Wind Circle 1
28 HT18028 Screw ST 4 x 75 2
29 HT18029 Stator 1
30 HT18030 Inductance 2
31 HT18031 Connection Spring 2
32 HT18032 Housing 1
33 HT18033 Name Plate1 1
34 HT18034 Rear Handle (Right) 1
35 HT18035 Switch 1
36 HT18036 Cable Grip 1
37 HT18037 Screw ST4 x 16 2
38 HT18038 Capacitor 1
39 HT18039 Switch Button 1
40 HT18040 Power Cord with Moulded Plug 1
41 HT18041 Cable Protector 1
42 HT18042 Screw ST4 x14 1
43 HT18043 Rear Handle (Left) 1
44 HT18044 Screw ST 4 x 16 2
45 HT18045 Screw ST 4 x 22 2
46 HT18046 Timing Switch 1
47 HT18047 Brush Cap 2
48 HT18048 Carbon Brush 2
49 HT18049 Brush Holder 2
50 Ht18050 Name Plate2 1
51 HT18051 Data Plate 1

501 HT180501 Spanner 1
502 HT180502 Polishing Backing Pad 1
503 HT180503 Artificial Lambs Wool Polishing Bonnet 1
504 HT180504 Sanding Backing Pad (Velcro) 1
505 HT180505 ‘D’ Shape Handle 1
506 HT180506 Allen Key 1
507 HT180507 Screw M10 x 25 1

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Parts Diagram

IMPORTANT:

The use of parts other than CLARKE replacement parts may result in safety hazards,
decreased tool performance and may invalidate your warranty.

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