Clarke APK900 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS GC11/11
HVLP Electric Spray Station
Model No: APK900
PART NO: 2310060

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
INTRODUCTION
Thank you for purchasing this CLARKE HVLP (highvelocity/low pressure)
Electric Spray Station.
Before attempting to use this product, please read this manual throughout
and follow the instructions carefully. Thoroughly familiarise yourself with this
product & its operation in order to ensure the safety of yourself and others
around you. In so doing, 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 it’s
intended purpose.
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.
Please note that 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.
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TECHNICAL SPECIFICATION

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
CONTENTS
INTRODUCTION ..................................................................................2
GUARANTEE ........................................................................................2
SPECIFICATION ...................................................................................2
GENERAL SAFETY PRECAUTIONS .......................................................4
ELECTRICAL CONNECTIONS ..............................................................7
OVERVIEW .......................................................................................... 8
OPERATING INSTRUCTIONS ................................................................9
GENERAL PREPARATION ..................................................................... 9
PAINT PREPARATION ........................................................................... 9
START-UP .............................................................................................. 10
ADJUSTMENTS ..................................................................................... 11
SPRAYING TECHNIQUE ....................................................................... 12
CLEANING & MAINTENANCE............................................................. 14
CLEANING ........................................................................................... 14
MAIINTENANCE .................................................................................. 15
FAULT FINDING ...................................................................................16
COMPONENT PARTS ...........................................................................17
DECLARATION OF CONFORMITY ....................................................... 19

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
GENERAL SAFETY PRECAUTIONS
WORK AREA
1. Keep the work area clean and well lit. Cluttered and dark areas invite
accidents.
2. Do not operate power operated tools in explosive atmospheres such as in
the presence of flammable liquids, gasses or dust. Power operated tools
can create sparks which may ignite dust or fumes.
3. Keep children and bystanders away while working. Distractions can cause
you to lose control.
ELECTRICAL SAFETY
1. Power operated tools must match the power outlet. Never modify the plug
in any way. Do not use adaptor plugs with earthed (grounded) power
tools. Correct plugs and outlets will reduce the risk of electric shock.
2. Do not expose tools to rain or wet conditions. Any water entering power
operated tools will increase the risk of electric shock.
3. Do not abuse the electrical cable. Never use the cable for pulling or
unplugging the machine. Keep the cable away from sources of heat, oil,
sharp edges or moving parts. Damaged or tangled cables increase the
risk of electric shock.
4. When operating a power operated tool outdoors, use an extension cable
suitable for outdoor use. Using the correct cable reduces the risk of
electric shock.
PERSONAL SAFETY
1. Stay alert, watch what you are doing and use common sense when you
are operating a power operated tool. Do not operate when you are tired,
ill or under the influence of alcohol, drugs or medication.
2. Wear personal protective equipment including eye protection. Safety
equipment such as a face mask, non-skid shoes or hearing protection
used for appropriate conditions will reduce personal injuries. Use a face or
dust mask if necessary. Wear ear protectors/defenders as the noise level
of this machine can exceed 85dB (A).
3. Do not over-reach. Keep your proper footing and balance at all times. This
enables better control in unexpected situations.
4. Avoid accidental starting of the machine. Ensure the switch is in the off
position and the locking button disengaged before plugging the machine
in to the power supply. Carrying power operated tools around with your
finger on the trigger or plugging in power tools that are switched on invites
accidents.

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5. Dress properly. Wear protective hair covering to contain long hair. For
best footing, wear rubber soled footwear. Keep floor clear of oil, scrap
wood, etc.
6. Concentrate on the job in hand, no matter how trivial it may seem. Be
aware that accidents are caused by carelessness due to familiarity.
POWER OPERATED TOOL USE AND CARE
1. Do not use the power operated tool if the switch does not turn it on and off.
Any power operated tool that cannot be controlled with the switch is
dangerous and must be repaired.
2. Always disconnect from the power supply before making any adjustments
or storing the machine. These measures will reduce the risk of the machine
starting accidentally.
3. Store power operated tools out of reach of children and do not allow
persons unfamiliar with these instructions to operate this product. Power
operated tools are potentially dangerous in the hands of untrained users.
4. Maintain in top condition. Keep tools/ machines clean for the best and
safest performance. Check for any condition that may affect the tool’s
operation. Many accidents are caused by poorly maintained power tools.
5. Use recommended accessories. The use of improper accessories could be
hazardous.
6. Machine cleanliness. Do not allow the ventilation slots in the machine to
become blocked with dust.
7. Check for damage before using the machine. Any damaged part should
be inspected 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 machine’s
operation. Any damage should be properly repaired or the part
replaced. If in doubt, DO NOT use. Consult your local dealer.
SERVICING
1. When necessary, have your power operated tools serviced or repaired by
a qualified person using identical replacement parts. This will ensure that
the safety of the tool is maintained.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
ADDITIONAL SAFETY PRECAUTIONS FOR PAINT SPRAYING
1. Never spray in the direction of persons or animals. Never allow the paint to
come into contact with the skin. In the case of injury, seek expert medical
advice immediately.
2. Always wear a suitable approved breathing mask when spraying, to
protect against inhalation of paint spray or fumes. An air feed mask may
be required when spraying some types of paint. If in doubt, check with the
paint manufacturer.
3. Always make sure there is adequate ventilation. Do not spray in confined
or enclosed areas.
4. Always disconnect the spray gun from the electrical supply when it is not
in use and before cleaning or dismantling.
5. Always adhere to the paint manufacturers instructions when thinning
paint.
6. Always disconnect from the power supply when filling the paint container.
7. Always thoroughly clean the spray gun after use. See ‘Maintenance’.
8. Never smoke while spraying or preparing paints, or spray near a naked
flame or heat source. Many paints are flammable.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
ELECTRICAL CONNECTIONS
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
Before switching the product on, make sure that the voltage of your
electricity supply is the same as that indicated on the rating plate. This
product is designed to operate on 230VAC 50Hz. Do not connect it to any
other power source.
This product may be fitted with a non-rewireable plug. If it is necessary to
change the fuse in the plug, the fuse cover must be refitted. If the fuse cover
becomes lost or damaged, the plug must not be used until a suitable
replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or
due to damage, it should be cut off and a replacement fitted, following the
wiring instructions shown below. The old plug must be disposed of safely, as
insertion into a mains socket could cause an electrical hazard.
WARNING! The wires in the power cable of this product are
coloured in accordance with the following code:
Blue = Neutral Brown = Live
If the colours of the wires in the power cable of this product do not
correspond with the terminal markings of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal which
is marked N or coloured Black.
• The wire which is coloured Brown must be connected to the terminal
which is marked L or coloured Red.
Plug must be BS1363/A approved.
Always fit a 5 Amp fuse.
Neutral Live
(Blue) (Brown)
Ensure that the outer sheath of the cable is firmly held by the clamp
We strongly recommend that this product is connected to the mains supply
via a Residual Current Device (RCD).
If in doubt, consult a qualified electrician. DO NOT attempt repairs yourself.
This symbol indicates that this is a Class II product and does not require
an earth connection.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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OVERVIEW
The High Volume/Low Pressure (HVLP) spray gun reduces the spray mist
associated with compressed air spraying and therefore both reduces paint
loss and masking requirements. The gun may be used with various spray
mediums, including varnishes, wood preservatives, masonry paints, enamel
paints, and oil and water based paints.
1 2
1.
3
4
5
11
6
10 6 7
8 12
9

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
OPERATION
GENERAL PREPARATION
Do not use textured wall paints or coatings as they are likely to block the
nozzle. To obtain the best results, it is important that you prepare the surface
to be sprayed and thin the paint to the correct viscosity before you operate
your spray gun. Always ensure that the surfaces to be sprayed are free from
dust, dirt and grease. Make sure that you have masked the areas that should
not be sprayed, using a good quality masking tape.
Paint to be sprayed should be thoroughly mixed and free from lumps or other
particles. Many substances can be sprayed with this spray gun, but always
check the manufacturers recommendations before purchasing your paint.
PAINT PREPARATION
ALWAYS REMEMBER TO DISCONNECT FROM THE MAINS SUPPLY BEFORE
FILLING THE PAINT CONTAINER WITH SPRAYABLE MATERIALS.
Most paints are supplied ready for brush application and will need to be
thinned before they are suitable to be sprayed. Follow the manufacturers
advice on thinning the paint when used with a spray gun. Using the viscosity
cup will help you to determine the correct viscosity of paint to be used.
To do this, fill the cup to the brim with the paint and measure the amount of
time it takes for the cup to empty back into the can. The table below shows
recommended times for different materials.
Material Runout Time
Emulsion paints 18 - 22 seconds
Thinner-soluable primers 25 - 40 seconds
Thinner-soluable varnishes 15 - 40 seconds
Water-soluable primers 25 - 40 seconds
Water-soluable varnishes 20 - 35 seconds
Automotive spray paint 20 - 35 seconds
Wood preservatives No thinning required
Wood stains No thinning required
If the paint takes longer than the recommended time to empty, further
thinning is required. Mix in a small quantity of the appropriate thinner and
repeat the viscosity test until the correct thickness is achieved. Some
sprayable materials contain particles and lumps which should be strained
before filling the paint container.

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
START-UP
1. Unscrew the container from the
spray gun and align the suction
tube to suit the angle of spraying.
•When spraying horizontal
surfaces or pointing the gun
downwards, turn the suction
tube forward (A). If spraying
objects at high level, turn the
suction tube back towards you
(B) as shown in Fig 1.
2. Fill the container with prepared
paint and screw the container onto the spray gun. Place the spray gun in
the holder of the machine base until ready to start spraying.
•Always place the spray gun base assembly on a clean surface to
avoid sucking in dust etc through the air filter.
3. Connect the air hose to both the
base and the spray gun as shown
in Fig 2.
4. Connect the spray gun to the
mains supply.
Fig 1
Suction
Tube
AB
Fig 2

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
ADJUSTMENTS
SPRAY PATTERN
Adjust the spray gun by rotating the nozzle and setting the tabs on the air cap
as shown. Three different spray settings can be chosen, depending on the
application and target object.
A) Flat, narrow jet (for horizontal surfaces)
B) Tall, narrow jet (for vertical surfaces)
C) Circular jet (for corners, edges and hard to reach areas)
A) horizontal flat jet B) vertical flat jet C) tabs back
•Note that both tabs must be adjusted as a pair.
SPRAY VOLUME
1.In order to achieve consistent and repeatable spray output, adjust the
spray volume by turning the trigger stop regulator on the rear of the spray
gun as shown in Fig 4.
•Turn as shown; +to increase
the volume of material and -
to reduce.
•Adjustment of the regulator will
also affect the pattern. A poor
spray pattern will concentrate
the paint in the centre of the
spray and give a blotchy finish.
A good spray pattern will give
even distribution of paint
across the pattern.
2. Aim the spray gun at a piece of scrap material and operate the trigger
until paint is spraying. Adjust the regulator until the required volume of
paint is spraying.
Fig 3
Fig 4

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
SPRAYING TECHNIQUE
The quality of the finished work depends on the smoothness and cleanliness
of the surface to be sprayed. Therefore the surface should be carefully
prepared and kept free from dust. Carefully mask all areas not to be painted
and cover all surrounding areas.
It is advisable to test the spray gun on cardboard or a similar surface to find
the correct setting. Start spraying outside the actual target area and pass
smoothly across the target without stoppages.
Control the speed of movement of the spray gun evenly. A fast speed of
movement over the surface will give a thin coat and a slow speed will give a
heavy coat.
Apply one coat at a time. If a further coat is required, make sure you observe
the manufacturer’s drying time recommendations before applying a second
coat. When spraying small areas, keep the regulator on a low setting. This will
avoid using too much paint and prevent overspray.
Where possible, avoid stopping and starting when spraying an object. This
can lead to too much, or not enough paint being applied to local areas. Do
not tilt the spray gun at more than 45O.
Hold the spray gun at an even distance from the target as shown in Fig 5 and
avoid an uneven movement.
RIGHT WRONG
Fig. 5

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
To obtain the best results, keep your spray gun level and parallel to the
surface at all times. Keep the nozzle 25 - 30 cm from the surface and spray
evenly from side to side or up and down. Do not spray at an angle as this will
lead to paint runs on the surface. Use smooth and even strokes. When
spraying large areas, using a criss-cross pattern as shown in Fig 6.
Fig 6

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
CLEANING AND MAINTENANCE
CLEANING
Continuous satisfactory operation depends upon proper care and regular
cleaning. It is essential that the spray gun is cleaned thoroughly after every
use. Failure to clean it will almost certainly result in blockages and it may not
operate correctly when you next come to use it. The following action must be
taken after every use:
1. Allow the remaining paint to flow back into the paint container. Empty any
remaining material from the container.
2. Clean the paint container and suction tube thoroughly with a brush.
3. Pour some thinners or water (as applicable) into the container and screw
back on. Turn the spray gun back on and spray into a container or cloth.
Repeat until only clean thinners is coming out of the nozzle.
4. Turn the spray gun off and empty the paint container completely of any
remaining thinners. Always ensure the container sealing disc is free of
paint residue and check for any damage.
5. Clean the outside of the spray gun and container with a cloth soaked in
thinners or water (as applicable).
6. Unscrew the union nut and
remove the air cap and nozzle.
Clean the air cap and nozzle with
a brush and thinners or water.
•Never clean the nozzle or air
holes with sharp metal objects.
Nozzle
Union Nut
Air Cap Tabs
Fig 7

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MAINTENANCE
1. Release the cover from the base
unit by pinching the side clips
together and lifting the cover off.
2. Inspect the condition of the air
filter.
3. The filter can be washed in soapy
water or it should be replaced if
badly fouled.
4. Replace the filter and the cover.
IMPORTANT: NEVER OPERATE WITHOUT THE AIR FILTER;- DIRT COULD BE
SUCKED IN AND INTERFERE WITH THE FUNCTION OF THE SPRAY GUN.
Check the power cable to ensure it is sound and free from cracks, bare wires
etc.
The nozzle parts may wear with long term use, depending on the
abrasiveness of the materials being sprayed. More abrasive materials, such as
emulsions, will cause faster wear.
A worn nozzle may eventually develop a larger hole and scratches on the
surface, which will cause a poor spray pattern. Replacements are available
from your dealer or the Clarke International Parts Department.
STORAGE
For long term storage, always store in a well ventilated area and keep the
product dry and dust free.
ENVIRONMENTAL PROTECTION
If disposing of this product or any damaged components, do not
dispose of with general waste. This product contain valuable raw
materials and must be disposed of according to the laws governing
Waste Electrical and Electronic equipment and should be taken to your
local civic amenity site for recycling.
Fig 8

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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
FAULT FINDING
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
COMPONENT PARTS - BASE ASSEMBLY
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
COMPONENTS PARTS - SPRAY GUN
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
DECLARATION OF CONFORMITY