Clarke Ranger 40, 2320503 User guide

RANGER 40 / 65 OIL FREE

RANGER 40 / 65 OIL FREE

AIR COMPRESSOR

AIR COMPRESSOR

OPERATION & MAINTENANCE

INSTRUCTIONS

0404

©

NOTES

Copyright: Clarke International. May, 2000

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Thank you for purchasing this CLARKE RANGER Oil Free Air Compressor, which is
designed for hobby and DIY use only. This machine is not designed to run
continuously when delivering pressures greater than 7 bar . Please refer to the
Duty Cycle details, under ‘Specifications on page 13.
Please read this leaflet thoroughly and carefully follow all instructions. In doing
so you will ensure the safety of yourself and that of others around you, and you
can look forward to the compressor 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 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 without prior permission. This guarantee does not effect your statutory
rights.

CONTENTS Page

SPARE PARTS AND SERVICE

For Spare Parts and Service,please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [email protected]

SERVICE: [email protected]

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Safety Precautions ................................................................................ 4

Assembly ................................................................................................ 5

Electrical Connections ......................................................................... 6

Operation............................................................................................... 7

Routine Maintenance........................................................................... 8

Troubleshooting ..................................................................................... 9

Paint Spraying Hints -..... General preparation ................................ 10

Preparing the paint.................................. 10

Handling the gun ..................................... 11

Spray gun maintenance ......................... 11

Parts Identification .............................................................................. 12

Spare Parts ........................................................................................... 12

Accessories .......................................................................................... 13

Specifications ...................................................................................... 13

Spare Parts and Service contacts ..................................................... 14

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SAFETY PRECAUTIONS

ACCESSORIES

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. It is in your own interest to read and pay attention

to the following rules:

1. COMPRESSED AIR IS DANGEROUS, NEVER direct a jet of air at people
or animals, and NEVER discharge compressed air against the skin.

2. DO NOT operate your compressor with any guards removed.

3. Electrical or mechanical repairs should only be carried out by a
qualified engineer . If problems occur, contact your Clarke dealer.

4. Before carrying out any maintenance, ensure the pressure is expelled
from the air receiver , and the machine is disconnected from the mains.

5. DO NOT leave pressure in the receiver overnight, or when transporting.

6. DO NOT adjust, or tamper with the safety valves. The maximum pressure
is factory set, and clearly marked on the machine.

7. DO NOT operate in wet or damp conditions. Keep the machine dry at
all times.

8. A clean atmosphere will ensure efficient operation. Do not use in dusty
or otherwise dirty locations.

9. Some of the metal parts can become quite hot during operation.
Take care not to touch these until the machine has cooled down.

10. Always adjust the pressure regulator to the recommended setting for
the particular spray gun or tool being used.

11. When spraying inflammable materials e.g. cellulose paint, ensure there
is adequate ventilation and keep clear of any possible source of
ignition.

12. Protect yourself. Think carefully about any potential hazards which
may be created by using the air compressor and use the appropriate
protection. e.g. Goggles will protect your eyes from flying particles.
Face masks will protect you against paint spray and/or fumes.

13. Before spraying any material always consult paint manufacturers
instructions for safety and usage.

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Your Clarke Ranger Oil Free Air Compressor can be used in conjunction with a range of
optional accessories for inflating tyres, air brushing, stapling, blowing and many other uses.
For details contact your local accessory stockist. A complete kit is available from your Clarke
dealer which is ideal for almost all applications.

Please quote part number 3110165

Should you experience any difficulties obtaining accessories, please contact the Clarke
sales department (telephone [phone]) for details of your nearest dealer.

SPECIFICATIONS

Electrical Supply................................................. 230 V, 1 Phase 50Hz

Motor Rating....................................................... 1.5 HP

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Max. Air Pressure ................................................ 8 bar (115 lbf/in

Air Displacement ............................................... 6.3 cuft/min

Air Receiver ....... Ranger 40 ............................. 24 litre

Ranger 65 ............................. 50 litre

Nett Weight........ Ranger 40 ............................. 18kg

Ranger 65 ............................. 30kg

Dimensions......... Ranger 40 ............................. 600x260x600mm

Ranger 65 ............................. 820x320x620mm

Duty Cycle .......................................................... S3 40% at 7bar**

Part No. .............. Ranger 40 ............................. 2320503

Ranger 65 ............................. 2320521

*The machine may not be run for more than 4 minutes in any 10 minute period at 7bar

*

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. Always consult the machine’s data plate

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)

PARTS IDENTIFICATION

14. Personal safety products can be obtained from your local dealer .

15. Do not exert any strain on electrical cables and ensure that air hoses
are not tangled or wrapped around machinery etc.

16. When disconnecting air hoses or other equipment from your
compressor ensure that the air supply is turned off at the machine
outlet and expel all pressurised air from within the machine and other
equipment attached to it.

17. Make sure that children and animals are kept well away from the
compressor and any equipment attached to it.

18. Always ensure that all individuals using the compressor have read
and fully understand the Operating Instructions supplied.

ASSEMBLY

The wheel assembly, and rubber foot, for the Ranger 40 are packed
separately. The method of assembly is shown on the packaging, and is
duplicated below.

1. Compressor

2. Air Inlet Filter

3. Thermal O’load Reset Button

4. Air Tank

5. Non-Return V alve

6. Delivery Pipe

7. Wheel

8. Antivibration Pad

(Valve)

9. Drain Valve

10. Pressure Regulator & Cutout

11. Air Tank Pr essure Gauge

13. Pressure Regulator Knob

14. Air Outlet

15. Handle

17. Safety V alve

18. ON /OFF Switch

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When attaching the wheels, do not tip the machine on to its side.

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ELECTRICAL CONNECTIONS

Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved 13 amp BS 1363 plug, or a suitably fused isolator
switch.

W ARNING! THIS APPLIANCE MUST BE EARTHED

IMPORTANT: The wires in the mains lead ar e coloured in accordance

with the following code:

Green & Y ellow - Earth

Blue - Neutral

Brown - Live

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

• Connect GREEN & YELLOW cord to terminal marked with a letter “E”

or Earth symbol “ ” or coloured GREEN or GREEN & YELLOW .

• Connect BROWN cord to terminal marked with a letter “L” or

coloured RED.

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

BLACK.

If this appliance is fitted with a plug which is moulded onto the electric
cable (i.e. non-rewireable) 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. When replacing a detachable fuse carrier, ensure 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.

FUSE RATING

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

We str ongly recommend that this machine is connected to the mains
supply via a Residual Current Device (RCD)

If in any doubt, consult a qualified electrician. DO NOT attempt any
repairs yourself.

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For a professional looking finish paint must be thinned. If the manufacturers
recommendations on thinning are not available, the following can be used as a
general guide: Water based paints (emulsions) - 10-20% water

Oil based paints (gloss) - up to 10% white spirit thinners

Cellulose paints - up to 50% cellulose thinners

3. HANDLING THE GUN

The first requirement for a good resultant finish is the proper handling of the gun.
The gun should be held perpendicular to the surface being covered and moved
parallel to it. The stroke should be started before the trigger is pulled and the
trigger should be released before the stroke is ended. This gives accurate control
of the gun and material.

The distance between gun and surface should be 6 to 12 inches depending on
material and atomizing pressure. The material deposited should always be even
and wet. Lap each stroke over the preceding stroke to obtain a uniform finish.

NOTE: To reduce overspray and obtain maximum efficiency, always spray

with the lowest possible atomizing air pressure.

4. SPRAY GUN MAINTENANCE

1. Immerse only the front end of the gun until solvent just covers the fluid
connection.

2. Use a bristle brush and solvent to wash off accumulated paint.

3. Do not submerge the entire spray gun in solvent because:
a. the lubricant in the gland packings will dissolve and the packings will dry

out.
b. the lubricant will dissolve causing harder operation and faster wear.
c. residue from dirty solvent may clog the narrow air passages in the gun.

4. Wipe down the outside of the gun with solvent dampened rag.

5. Lubricate gun daily. Use a light machine oil on:
a. fluid needle packing.
b. air valve packing.
c. fan control packing.
d. trigger pivot point.

Coat the fluid control spring with vaseline.

Caution: Never use lubricants containing silicone as this may cause finish defects.

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PAINT SPRAYING HINTS

OPERATION (Numbers in brackets refer to fig. 1 below)

WARNING

NEVER attempt to spray unless you are wearing suitable, approved

respiratory and eye protection.

REMEMBER that some modern paints require specialist respiratory

protection...always consult the paint manufacturers instructions.

1. GENERAL PREPARATION

a. Ensure that the area in which you will be spraying is clean and dust free.
b. Connect spray gun to compressor via suitable flexible hose.
c. With no paint in spray gun, test system for air leaks.
d. Cover adjacent pieces of equipment to prevent overspray. Mask areas

of the article not to be sprayed.

e. Ensure surface to be painted is clean, dry and free from oil and dust.

Check paint manufacturer’s instructions for any special surface
preparation required.

REMEMBER - TIME SPENT PREPARING SAVES TIME SPENT FINISHING

2. PAINT PREPARA TION

a. Achieve the correct paint viscosity. This should be done according to

paint manufacturer’s instructions, and will vary according to type of paint.

b. Having mixed the paint thoroughly in a separate container, pour into the

spray gun paint container through a fine filter.

DO NOT OVERFILL SPRAY GUN PAINT CONTAINER - three quarters full is maximum

c. It is usually best to experiment with a couple of practice spray coats on a

piece of material with the same type of surface as the article you wish to
spray, eg. metal for a car body panel, wood for a piece of furniture etc.

Some common problems:

PROBLEM CAUSE CORRECTION

Paint does not atomise Paint is too thick, air Add thinners
(comes out in blobs) pressure is too low. Increase air pressure (not

above 50 psi, unless specified by paint manuf.

Paint dries before hitting Paint is too thin. Air Add more paint.
surface, leaving it dry pressure is too high Reduce air pressure
with a rough texture

Finish is pitted like Air pressure too high Reduce air pressure,
Orange peel or spray too close to increase distance between

work gun and work.

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Before connecting your Ranger to the mains supply, check the following:-

• The mains voltage is 230V.

• The ON/OFF control knob (3) is in the OFF (lower) position.

• The pressure regulator (5) should be set at its lowest setting, i.e. turned fully
anticlockwise, and the tap (6) screwed IN to its closed position.

• If the machine has not been used for 24 hours or so, open the air receiver
drain valve (9) to drain any condensate which may have accumulated. When
clear, close the valve, finger tight.

IMPORTANT: If the receiver is under pressure, keep your hands well away fr om the

air being expelled.... remember, compressed air is DANGEROUS!

Fig.1

1. Air Filter

2. Thermal Overload Reset Button

3. ON / OFF Knob

4. Pressure Regulator and Cutout

5. Air Pressure Regulator Knob

6. Air Outlet Tap

7. Quick Fit Coupling Nut

8. Air Tank Pressure gauge

9. Drain Valve

10. Antivibration Pad (Foot)

Now connect a suitable air hose, fitted with quick-fit adaptors, between the air
outlet (7) and the spray gun or air tool being used.

Ensure that the rubber washers are in place to form the necessary air tight seals.
These fittings should be screwed by hand but take care not to over tighten. If a
rubber seal is damaged then it should be replaced.

If you do not wish to use the Quick Fit method of hose connection, simply remove
the Quick Fit nut and use an air hose fitted with conventional 1/4 BSP connectors.

Once the hose connections are complete, CHECK AGAIN to ensure the pressure
regulator (5) is turned fully anticlockwise so that compressed air cannot reach the
air tool, then switch the compressor ON, by lifting the ON/OFF knob (3), until it
clicks into the upper position.

The air compressor will now start, and pressure will build up in the receiver to a
regulated max. pressure of 8 Bar (115 psi).

Should the motor fail to start immediately, it is probable that the air receiver is
already full of air . Check the tank pressure gauge (8). If you release air , by opening
air outlet tap (6), the motor will start automatically once the cut-in pressure is
reached.

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If this is not the case, it is possible that the overload cutout has intervened. This is a
safety device to prevent the motor from overheating. The device will reset when
the temperature falls to a predetermined level. In this event, switch OFF the
machine and wait for 5 - 10 minutes, before pressing the RESET button (2).

Switch ON the machine and try again. If the motor fails to start, after several
attempts, consult your Clarke dealer.

Once the machine has started, turn ON the air supply to your air tool by opening
the tap (6), and turn the pressure regulator (5) clockwise so that your chosen
setting, shown on the label on top of the regulator knob, is opposite the inverted
vee mark on the side of the casting. Note that the pressure gauge registers the
pressure in the air receiver only.

Check to ensure that there are no air leaks at any of the couplings or in other
parts of the system before operating the spray gun or air tool in the normal way.

When the compressor reaches its maximum working pressure, the motor will
automatically cut out, and will restart when the pressure has fallen by approximately
20 psi. This automatic STOP/ST ART process will continue, as necessary, to maintain
pressure in the receiver.

When you have finished the job in hand ALWAYS switch OFF at the ON/OFF switch,
NOT the mains supply, and release any pressure remaining in the system by opening
the drain valve until all air is expelled. This also allows any condensate to drain off.

Operate the air tool to further ensure that there is no pressure in the system before
disconnecting the tool. Finally, reset the pressure regulator to zero by turning the
knob fully anticlockwise.

TROUBLE SHOOTING

With considerate use, your CLARKE Air Compressor should provide you
with long and trouble free service. Routine checks should be made on
both the electrical supply as well as on all the compressed air lines and
connections. If any fault appears, the reason for which is not immediately
obvious, we recommend that you contact your local CLARKE Dealer.

PROBLEM

The compressor
stops and will
not start again.

PROBABLE CAUSE

Bad connections.

Overload cutout
switch has tripped.

Motor windings
burnt out.

REMEDY

Check electrical
connections.
Clean and tighten as
necessary.

Switch off and wait 5 minutes

before switching on.
Contact your local dealer

for a replacement motor.

ROUTINE MAINTENANCE

IMPORTANT: Before carrying out any of this service work, always disconnect the
machine from the mains supply, drain the air receiver and, if necessary, allow the
machine to cool down before starting work.

Daily

Before use, always open the drain valve to ensure that any condensate, which
may have accumulated, is drained off.

Monthly

It is important to keep the Compressor clean, with the help of a small soft brush
and vacuum cleaner. In particular, the air intake filter should be inspected at least
MONTHLY, and more often in dusty conditions, so that it is always kept free of any
dirt particles, which if not cleaned away, will affect
the performance of the machine.

To clean the air intake filter, carefully prise out the
sponge element shown in fig.2. Clean the sponge
and the inner housing using a soft brush.

If necessary, the sponge filter may be gently washed
in warm soapy water, rinsed and allowed to dry
thoroughly before refitting.

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Fig.2

The compressor

does not reach
the set pressure
and overheats
easily.

Compressor head
gasket blown or
valve broken.

Wait for compressor to cool
down, disassemble head
and replace any broken
components. Carefully
clean all sealing surfaces
before reassem-bling. If in
doubt contact your CLARKE
dealer.

Compressor
does not start.

Air receiver charged

Open drain cock to expel
air . Compressor should start
again when pressure
reduces to approx. 95 psi.

CAUTION Do not attempt any repair or adjustment if you are uncertain as
to how it should be done. If you have any queries, contact your local
CLARKE Dealer.

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