Clarke CAS110 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS GC02/12
Airless Spray Gun
Model No: CAS110
PART NO: 2310050

2
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
INTRODUCTION
Thank you for purchasing this CLARKE Airless Spray Gun.
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.
011SAC
rebmuNtraP0500132
thgieWgk6.1
)HxWxL(snoisnemiDmm042x511x012
yticapacreniatnoClm008
etarwolfelzzonmumixaM)retaw(nim/lm023
tupnirewopdetaRW011
egatloVzH05/V042-022
ssalCnoitalusnIIIssalC
TECHNICAL DATA

3
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
CONTENTS
INTRODUCTION ..................................................................................2
GUARANTEE ........................................................................................2
TECHNICAL DATA ...............................................................................2
GENERAL SAFETY PRECAUTIONS .......................................................4
ELECTRICAL CONNECTIONS ..............................................................7
OVERVIEW ..........................................................................................8
OPERATING INSTRUCTIONS ................................................................ 9
CLEANING & MAINTENANCE.............................................................12
TROUBLESHOOTING ...........................................................................14
VIBRATION EMISSIONS .......................................................................15
COMPONENT PARTS ...........................................................................17
DECLARATION OF CONFORMITY.......................................................19

4
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. Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
ELECTRICAL SAFETY
1. Power 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 power tools to rain or wet conditions. Any water entering
power tools will increase the risk of electric shock.
3. Do not abuse the electrical cable. Never use the cable for pulling or
unplugging the power tool. 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 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 tool. Do not operate a power tool 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 dust 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 of the power tool in unexpected situations.
4. 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.
5. Concentrate on the job in hand, no matter how trivial it may seem. Be
aware that accidents are caused by carelessness due to familiarity.

5
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
POWER TOOL USE AND CARE
1. Do not use the power tool if the switch does not turn it on and off. Any
power tool that cannot be controlled with the switch is dangerous and
must be repaired.
2. Store power tools out of the reach of children and do not allow persons
unfamiliar with these instructions to operate the tool. Power tools are
potentially dangerous in the hands of untrained users.
3. Maintain power tools in top condition. Check for any condition that may
affect the power tool’s operation. Many accidents are caused by poorly
maintained power tools.
4. Use recommended accessories. The use of improper accessories could be
hazardous.
5. Machine cleanliness. Clean the spray gun routinely as described under
MAINTENANCE. Do not allow the ventilation slots in the housing to become
blocked with dust.
6. Check for damage before using the tool. Any damaged part should be
inspected to ensure that it will operate properly and perform its intended
function. Check for any 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 tools serviced or repaired by a
qualified person using identical replacement parts. This will ensure that the
safety of the power tool is maintained.
FURTHER 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 make sure there is adequate ventilation. Do not spray in confined
or enclosed areas.
3. 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.
4. Always disconnect the spray gun from the electrical supply when it is not
in use, and before cleaning or any disassembly.
5. Always keep the spray nozzle in place when spraying.
6. Always adhere to the paint manufacturers instructions when thinning
paint.

6
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
7. Always disconnect from the mains supply when filling the paint container.
8. Always thoroughly clean the spray gun after use and lubricate the piston.
See ‘Maintenance’.
9. Never smoke while spraying or preparing paints, or spray near a naked
flame or heat source. Many paints are flammable.
10. Never use the spray gun outdoors when it is raining.

7
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 220-240VAC 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 3 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.

8
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
OVERVIEW
Airless spraying reduces the mist associated with compressed air spraying and
therefore reduces paint loss. Your sprayer may be used with various spray
mediums, including varnishes, wood preservatives, masonry paints, enamel
paints, and oil and water based paints.
1. 2
3
4
5
8
6
79
10
1gnisuoHrotoM6looTgnikcolbnUelzzoN
2lortnoCtuptuO7)2(sevlaVerapS
3reggirT8elzzoNerapS
4teksaByarpS9puCytisocsiV
5renia
tnoCtniaP01hcnerWesaeleRelzzoN

9
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
OPERATING INSTRUCTIONS
PREPARATION
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.
The paint or fluid to be sprayed should be thoroughly mixed and free from
lumps or other particles. Many substances can be sprayed with your spray
gun, but always check the manufacturer’s recommendations before
purchasing your paint. Do not use textured wall paints or coatings as this will
block the nozzle.
THINNING
ALWAYS REMEMBER TO DISCONNECT FROM THE POWER SUPPLY BEFORE
FILLING THE PAINT CONTAINER.
Most paints are supplied ready for brush application and will need to be
thinned before they are suitable to be sprayed. Follow the manufacturer's
advice on thinning the paint when used with a spray gun. 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 time it takes for the
cup to empty back into the can. The table below shows recommended times
for different types of material.
Plastic & latex paint 24 - 28 seconds
Water based paint 20 - 25 seconds
Primers 24 - 28 seconds
Varnishes 20 - 25 seconds
Oil based paints 18 - 22 seconds
Enamel paints 18 - 22 seconds
Aluminum paints 22 - 25 seconds
Car underseal 25 - 35 seconds
Wood sealers 28 - 35 seconds
Wood preservatives No thinning required
Wood stains No thinning required

10
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
If the paint takes longer than the recommended time to empty, then further
thinning is required. Mix in a small quantity of the appropriate thinner and use
the viscosity test until the correct consistancy is achieved. Some sprayable
materials contain particles and lumps. These materials should be strained
before filling the paint container.
OPERATING THE SPRAY GUN
1. Fill the paint container with the correctly
thinned and strained paint and connect
the spray gun to the mains supply.
2. Aim the spray gun at a piece of scrap
material and operate the trigger switch until
paint is spraying.
3. Adjust the output control until the required
volume of paint is spraying. Turn the output
control in a clockwise direction (B) to
reduce the flow and anti-clockwise (A) to
increase the flow.
•Adjustment of the output control will 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 throughout the pattern.
SPRAYING TECHNIQUES
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.
B
A
Fig. A
RIGHT WRONG FIG B

11
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
When spraying large areas, using a
criss-cross pattern as shown in Fig C.
Never start or stop the spray gun
while it is aimed at the surface to be
sprayed. Evenly control the speed of
movement of the spray gun.
•Moving quickly over the surface
will give a thin coat and slow
movement will give a heavy
coat.
•Apply one coat at a time. If a
further coat is required, make
sure you observe the
manufacturers drying time
recommendations before
applying a second coat.
•When spraying small areas, keep
the output control 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. Do not tip the
spray gun to more than 45O.
Fig C

12
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
CLEANING AND MAINTENANCE
ROUTINE CLEANING
ALWAYS REMEMBER TO DISCONNECT FROM THE MAINS SUPPLY BEFORE
CLEANING THE SPRAY GUN OR PAINT CONTAINER.
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 when you next come to use it! The guarantee does not cover
cleaning a sprayer that has not been properly cleaned by the user. The
following action must be taken after every use:
1. Empty any remaining material from the paint container.
2. Clean the paint container thoroughly with the thinner that was used.
3. Pour some thinner into the paint container and spray through the spray
gun until only clean thinner is coming out of the nozzle.
4. Thoroughly clean the paint pick up pipe and filter with thinner.
5. Clean the spray basket and nozzle and remove paint that remains.
6. Turn the spray gun upside down and apply a few drops of light oil to the
two apertures (A). This will lubricate the piston and cylinder.
INTERNAL CLEANING
If your spray gun should require extra internal cleaning, it may be necessary
to dismantle it. If so, the following action should be taken:
C
A A B
D
E
F
G

13
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
1. Remove the plug from the mains socket.
2. Remove paint container, pick up pipe and filter.
3. Take off the pump assembly.
4. Release the nozzle (B), valve (C), piston rod (D) and spring (E).
5. Clean the O-ring (F), and cylinder (G) and all parts thoroughly with solvent.
6. Apply a few drops of light lubricating oil to the piston, spring and cylinder.
7. Reassemble the spray gun.
LONG TERM MAINTENANCE
Please be aware that certain parts of this spray gun may wear with long term
use, requiring replacement and that these parts are not covered by your
guarantee.
These parts include the valve, spray nozzle, piston and spring. The wear on
these parts depends on the abrasiveness of the materials being sprayed.
More abrasive materials, such as emulsions, will cause these parts to wear
much faster.
Worn valves and nozzles will have larger holes and scratches on the internal
surfaces. This is likely to cause a poor spray pattern and will eventually require
replacing. Replacement valves are available from your dealer or the Clarke
International Parts Department.
Check the power cable to ensure it is sound and free from cracks, bare wires
etc before use.
STORAGE
1. For long term storage, always store in a well ventilated area and keep the
spray gun dry and dust free.
ENVIRONMENTAL PROTECTION
If disposing of this product or any damaged component, do not
dispose of it with general waste. This product contains valuable raw
materials which should be taken to your local civic amenity site for
recycling.

14
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
TROUBLESHOOTING
MELBORP ESUAC NOITULOS
seodtubsmuhrotoM
siyarpsroyarpston
.ralugerri
ehtnitonepippu-kciP
.noitisopthgir
.epippu-kciptsujdA
epippu-
kcipdekcolBsrennihthtiwepippu-kcipnaelC
elzzondekcolBelzzonnaelC.srennihthtiw
retlifdekcolB.srennihthtiwret
lifnaelC
sdeenlortnoctuptuO
.tnemtsujda
nosatiusotlortnoctuptuotsujdA
.01egap
roopsinoitasimotAtontnemtsujd
aemuloV
.tcerroc
.lortnoctuptuoehttsujdA
kcihtoottniaP.tniapfoytisocsivkcehC
.gnitniaprevOtonronaelctonnuG
n
ignitluserdetacirbul
rednilycnignikcitsnotsip
naelcdnanugyarpseltnamsiD
.rennihthtiw
.tniaphcumooTotesiwkc
olcemulovehttsujdA
nihtowtylppA.gniyarpsecuder
.tniapfostaoc
.nihtoottniaP.ytisocsivkcehC
nahtreduolrotoM
.
lamron
tonronaelctonnuG
gnisuac,detacirbul
.rednilycnikcitsotnotsip
naelcdnanugyarpseltnamsiD
.rennihthtiw
dnuosroyarpsoNrewoplacirtceleoN.ylppusrewopkcehC
tondnuosgnitarepO
.lamron
tnemtsujdatuptuorooP.lortnoctupt
uotsujda-eR
nitniaphguonetoN
rianignitluserreniatnoc
.nidekcusgnieb
.tniaphtiwllifeR
ylreporptontniaP
gniss
aptonrodetulid
epippu-kcip
.yletelpmoc
pu-kcipfossenilnaelckcehC
.tniapfoytisocsivdnaepip
roleepegnarO
.gni
ggofevissecxe
.desutnevlostcerrocnI.tnevlostnereffidesU
morfrafootnugyarpS
.ecafrus
ehtotresolcnugyarpsdlo
H
.ecafrus
.kcihtoottniaP.tniapehtnihT

15
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
VIBRATION EMISSIONS
MODEL No: CAS110
DESCRIPTION: AIRLESS SPRAY GUN
Declared vibration emission value in accordance
with EN12096.
Measured vibration emission value - a: 11.53m/s2
Uncertainty value - K: 1.5m/s2
Values determined according to EN28622-1
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 Hertz is potentially damaging and is most
hazardous in the range from about 5 to 20 Hertz.
Operators who are regularly exposed to vibration may suffer from Hand Arm
Vibration Syndrome (HAVS), 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 specification panel below.
HAND-ARM VIBRATION

16
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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/s2are considered hazardous when used for
prolonged periods. A tool with a vibration value of 2.8 m/s2may 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
above 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.

17
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
COMPONENT PARTS DIAGRAM

18
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
COMPONENTS PARTS LIST
oN noitpircseD oNtraP oN noitpircseD oNtraP
1hcnerWelzzoNyarpS10011SACJJ52daeHrebbuR52011SACJJ
2etalPelzzoN20011SACJJ62ydoBretsujdA62011SACJJ
3elzzoNyar
pS30011SACJJ72bonKtnemtsujdA72011SACJJ
4daeHnoitasimotA40011SACJJ82daPpirGraeR82011SACJJ
5gnirpS50011SACJJ92niPnoitc
irF92011SACJJ
6daeHevlaV60011SACJJ03niPnoitcirF03011SACJJ
7teksaByarpS70011SACJJ13eriWgnitcennoC13011SACJJ
8rednilyC8
0011SACJJ23hctiwS23011SACJJ
9gniR-O90011SACJJ33eveelSelbaC33011SACJJ
01gniR-O01011SACJJ43dnalGelbaC43011SACJJ
11gnirpS1
1011SACJJ53pirGeriW53011SACJJ
21doRnotsiP21011SACJJ63wercS63011SACJJ
31retuOtengam-ortcelE31011SACJJ73daPpirGtnorF73
011SACJJ
41wercS41011SACJJ83ebuTpukciP83011SACJJ
51taeSpilC51011SACJJ93reggirT93011SACJJ
61gnirpSfaeL61011SACJJ04renia
tnoCtniaP04011SACJJ
71etalPsserPemarF71011SACJJ14rehsaWgnilaeS14011SACJJ
81ylbmessAlioCrennI81011SACJJ24esaBrenia
tnoC24011SACJJ
91eveelS91011SACJJ34niPlloR34011SACJJ
02gulPhctiwS02011SACJJ44niFgnipmaD44011SACJJ
12emarFpmuP12011SAC
JJ54)H/R(gnisuoH54011SACJJ
22niPnoitcirF22011SACJJ64wercS64011SACJJ
32evirDcitengamortcelE32011SACJJ74lebaL74011SACJ
J
42)H/L(gnisuoH42011SACJJ

19
Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
DECLARATION OF CONFORMITY