Clarke Ranger 25A Operating manual

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Thank you for purchasing this CLARKE RANGER25 Oil Free Air Compressor,
which is designed for hobby and DIY use only.
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
Safety Precautions ...................................................................... 4
Assembly ...................................................................................... 5
Electrical Connections ............................................................... 6
Operating Instructions ................................................................ 7
Routine Maintenance ................................................................ 8
Troubleshooting ........................................................................... 9
Accessories ................................................................................ 10
Specifications ............................................................................ 10
Paint Spraying Hints - General preparation......................... 11
Preparing the paint ........................... 11
Handling the gun ............................... 12
Spray gun maintenance .................. 12
Parts List ...................................................................................... 13
Parts Diagrams ................................................................... 14 - 15

SAFETY PRECAUTIONS
WARNIN G
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. NEVER direct a jet of air at people or animals, and NEVER discharge
compressed air against the skin. COMPRESSED AIR IS DANGEROUS,
2. NEVER 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. NEVER leave pressure in the receiver overnight, or when transporting.
6. NEVER adjust, or tamper with the safety valves. The maximum pressure
is factory set, and clearly marked on the machine.
7. NEVER operate in wet or damp conditions. Keep the machine dry at
all times.
8. NEVER use in dusty or otherwise dirty locations. A clean atmosphere
will ensure efficient operation.
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. ALWAYS ensure there is adequate ventilation when spraying
inflammable materials e.g., cellulose paint, and keep clear of any
possible source of ignition.
12. ALWAYS 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. ALWAYS consult paint manufacturers instructions for safety and
usageBefore spraying any material .
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14. Personal safety products can be obtained from your local dealer.
15. NEVER 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 ALWAYS 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. ALWAYS keep children and animals 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, handle grip and rubber foot are packed separately.
The method of assembly is shown on the packaging, and is duplicated
below.
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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.
WARNING! THIS APPLIANCE MUST BE EARTHED
IMPORTANT: The wires in the mains lead are coloured in accordance with the
following code:
Green & Yellow - 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. 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.
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 strongly 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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OPERATION (Numbers in brackets refer to fig. 1 below)
Before connecting your Ranger25 to the mains supply, check the
following:-
• The mains voltage is 230V.
• The ON/OFF control knob (1) is in the OFF (lower) position.
• The pressure regulator (2) should be set at its lowest setting, i.e. turned
fully anticlockwise, and the tap (3) screwed IN to its closed position.
• If the machine has not been used for 24 hours or so, open the air
receiver drain valve (6) 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
from the air being expelled.... remember, compressed air is DANGEROUS!
Now connect a suitable air hose, fitted with quick-fit adaptors, between
the air outlet (4) 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 retaining 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 (2) is turned fully anticlockwise so that compressed air
cannot reach the air tool, and switch the compressor ON, by lifting the
ON/OFF knob (1), until it clicks into the upper position. The air compressor
will now start, and pressure will build up in the receiver to a regulated
maximum pressure of 115 psi (8 Bar) as indicated on the pressure gauge (5).
Fig.1
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ROUTINE MAINTENANCE
Daily before use, always open the drain valve to ensure that any
condensate, which may have accumulated, is drained off.
It is important to keep the CLARKE Air Compressor clean, and this may be
done 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. Also,
particles must not at any time be allowed to pass through into the cylinder
head as this would adversely affect the valves, possibly causing damage,
and entail more extensive dismantling and cleaning.
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.
To clean the air intake filter, carefully prise off the plastic cover and remove
the sponge element from inside. (See fig.1, item 7). 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. Ensure that the outer
filter cover is then clipped back into its original position. If any part of the
filter is damaged then you should obtain a replacement.
Turn ON the air supply to your air tool by opening the tap (3), and turn the
pressure regulator (2) 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/START 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.
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TROUBLE SHOOTING
With considerate use, your CLARKE Air Compressor should provide you
with a long and trouble free period of operation. 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.
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.
PROBLEM PROBABLE CAUSE REMEDY
Motor windings
burnt out. Contact your local dealer
for a replacement motor.
Switch off and wait 5
minutes before switching on.
Overload cutout
switch has tripped.
The compressor
stops and will
not start again.
Bad connections. Check electrical
connections.
Clean and tighten as
necessary.
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 reassembling. 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.
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SPECIFICATIONS
Electrical Supply ............................. 230 V, 1 Phase 50Hz
Motor Rating ................................... 1.5 HP
Max. Air Pressure ............................. 115 lbf/in2
Max. Air Pressure ............................. 8 bar
Air Displacement ............................ 7 cuft/min
Air Receiver ..................................... 24 litre
Weight (Packed)............................. 26kg
Dimensions ...................................... 660x330x630mm
ACCESSORIES
Your RANGER 25 Oil Free compressor can be used with a wide range of
optional accessories, for inflating tyres, paint spraying, air brushing,
stapling, blowing etc. For details, please contact your dealer or your
local dealer.
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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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PAINT SPRAYING HINTS
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 PREPARATION
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.
d. 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 workpiece
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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.
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.
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PARTS LIST
No. Description Qty Part No.
1 Air Reservoir 1 FN168HQ1000V
2 Plug 2 FN011008000
3 Wheel Insert 2 FN168HQ0004
4 Wheel 2 FN020188000
5 Washer 2 FN014005006
6 Nut 2 FN014003005
7 Drain Valve 1 FN022020000
8 Foot Antivibration 1 FN020146000
9 Screw 2 FN014013042
10 O-Ring 1 FN010041000
11 Spring 1 FN047113002
12 Element 1 FN047113001
13 Valve Kit 1 FN347043000
14 Tube 1 FN046001000
15 Connector 1 FN199110140
16 Pressure Gauge 1 FN330004000
17 Connector 1 FN011017000
18 Pressure Regulator 1 FN319044000
19 Tap Assembly 1 FN322007000
20 Regulator Assy. 1 FN321053000
21 Valve 1 FN347022000
22 Power Cable 1 FN101GA0200
23 Handle 1 FN020147000
24 Tube 1 FN117HL0010
- Wheel Kit compl. FN117HL0010
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: [e-mail]
SERVICE: [email protected]
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No. Description Qty Part No.
25 Filter Assembly 1 FN317028000
26 Comp. Head 1 FN116005031
27 Head Bolt 4 FN014013027
28 Head Gasket 1 FN116005017
29 Valve Block 1 FN416005008
30 Ring Silicone 1 FN010057000
31 Cylinder 1 FN016005007
32 Bearing 6203 1 FN033059000
33 Piston Assy. 1 FN416005002
34 Screw 1 FN014002027
35 Washer 1 FN116010013
36 Fan 1 FN116010004
37 Shaft 1 FN116115001
38 Crankcase Hsg. 1 FN016010007
39 Bolt 3 FN014002121
40 Bearing 6204 1 FN033028000
41 Rotor 1 FN034133000
42 Stator 1 FN316115604
43 Bearing 6202 1 FN033070000
44 Spring Ring 1 FN027011000
45 Housing 1 FN016010016
46 Nut 3 FN014004001
47 Capacitor 1 FN009200014
48 Fuse Protection 8A 1 FN008040000

PARTS DIAGRAM
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