Clarke BOXER 14 150L Belt Driven Air Compressor Instruction Manual

Clarke BOXER 14 150L Belt Driven Air Compressor Instruction Manual

INTRODUCTION

Thank you for purchasing this CLARKE 150L Belt Driven Air Compressor.

Read this manual fully before use and follow the instructions carefully. In doing so you will ensure the safety of yourself and those around you, and you can look forward to your purchase 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.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the obligation to deal with the WEEE in accordance with the WEEE regulations in relation to the treatment, recycling & recovery and environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with general household waste. It must be disposed of according to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.

SAFETY PRECAUTIONS

Before using your compressor it is in your own interest to read and pay attention to the following safety rules.

1. Compressed air is dangerous. Do not point a jet of air at persons or animals, and do not discharge compressed air against the skin.
2. DO NOT operate your compressor with the guard removed.
3. Repairs must only be carried out by a qualified engineer. If problems occur, contact your Clarke dealer.
4. Before carrying out any maintenance, make sure that the pressure is released from the air reservoir, and that the compressor is disconnected from the  electrical supply.
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 compressor.
7. DO NOT operate in wet or damp conditions. Keep the compressor dry at all times. Similarly, clean air will allow the compressor to work efficiently. Do not use in dusty or otherwise dirty locations.
8. Some of the metal parts can become quite hot during operation. Do not touch/ remove these until the compressor has cooled down.
9. Always set the pressure regulator to the recommended setting for the tool.
10. When spraying flammable materials e.g. cellulose paint, ensure that there is sufficient airflow and keep clear of any source of ignition.
11. Before spraying any material always consult paint manufacturers instructions for safety and usage.
12. Protect yourself. Goggles will protect your eyes from flying particles. Face masks will protect you against paint spray and fumes.
13. Do not apply strain to electrical cables and make sure that air hoses are not kinked or wrapped around the compressor.
14. When disconnecting air hoses or other equipment from your compressor, make sure that the air supply is turned off at the outlet and vent all pressurised air from within the reservoir and other equipment attached to it.
15. Make sure that children and animals are kept well away from the compressor and any equipment attached to it.
16. Make sure that all individuals using the compressor have had the necessary training and have read and fully understand these operating instructions.
17. Make sure that any equipment or tool used in conjunction with your compressor, has a safe working pressure exceeding that of the compressor.
18. Be careful when transporting the compressor to prevent tipping over
19. Permanently installed systems must be installed by a competent engineer.
20. This compressor produces noise levels in excess of 70dB(A). Persons working near the compressor must be supplied with ear protection.

SAFETY SYMBOLS

 Read this instruction booklet carefully before positioning, operating or adjusting the compressor.

 Risk of electric shock. The compressor must be disconnected from the mains supply before removing any covers. Do not use in a damp environment.

 Risk of accidental start-up. The compressor could start automatically in the event of a power cut and subsequent reset. Do not carry the compressor while it is connected to the power source, or when the tank is filled with compressed air.

 This compressor contains surfaces which may reach a high temperature during operation. Never operate with the motor housing removed.

 Wear safety goggles and ear protectors when using this compressor

 This compressor produces a high sound level during operation. Ear protection should be worn.

ELECTRICAL CONNECTIONS

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY.

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.

If the plug has to be changed because it is not suitable for your socket, or
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely, as insertion into a power 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 YELLOW AND GREEN = EARTH

If the colours of the wires in the power cable do not agree with the markings
on the plug.

• The BLUE wire must be connected to the terminal which is marked N or coloured black.
• The BROWN wire must be connected to the terminal which is marked L or coloured red.
• The YELLOW AND GREEN wire must be connected to the terminal which is marked E or or coloured green.

We strongly recommend that this machine is connected to the mains supply through a Residual Current Device (RCD)

If you are not sure, consult a qualified electrician. DO NOT try to do any
repairs.

BEFORE USE

CAUTION: TO PREVENT INJURY, GET ASSISTANCE WHEN LIFTING OR MOVING THIS COMPRESSOR.

Before connecting your compressor to the power supply, check the following:-

• Set the ON/OFF switch to the OFF position (pushed down).
• Make sure that the compressor is on level ground.
• Make sure that the supply voltage matches the voltage shown on the data label.

CHECK THE OIL LEVEL

1. Remove the dipstick from the oil reservoir.

2. Ensure the oil level is between the min and max marks on the dipstick.

• Only use SAE30 compressor oil, available from your Clarke dealer Part No. 3050801
• Take care not to exceed the maximum mark.

OPERATION

If the compressor has not been used for more then 24 hours, open the drain
valve (on the bottom of the reservoir) and drain any condensate which has
collected. See page 10.

MOVING THE AIR COMPRESSOR

• Stop the compressor and disconnect it from the power supply before you move it.
• Always use the handle.
• Do not lift by (or put strain on) valves or hoses.

ATTACHING AIR TOOLS

WARNING: BEFORE CONNECTING AIR TOOLS, MAKE SURE THAT YOU READ THE INSTRUCTIONS SUPPLIED WITH THE TOOL, ALSO ENSURE THAT THE TOOL IS SUITABLE FOR USE WITH THE COMPRESSOR AND HOSE SPECIFICATIONS.

1. Fit the supplied tap to the compressor and attach the air hose to the tap.

2. Attach the air tool to the other end of the air hose.

3. Turn the tap handle to the open position.
   NOTE: The tap is shown without the air hose fitted for clarity.

TURNING THE COMPRESSOR ON

1. Plug the compressor into the power supply.
2. Lift the On/Off button.

• The compressor will operate until the reservoir is fully pressurised. It will then shut down.
• The compressor will start up again when the pressure in the reservoir decreases.

CHECK THE SAFETY VALVE

To make sure that the safety valve works correctly.

1. Twist the knurled part of the safety valve.
   • Air will be released when you twist and stop when released.
2. If the valve does not operate in this way, do not use the compressor. The compressor must be repaired by a qualified service agent.

WARNING: DO NOT REMOVE OR TRY TO ADJUST THE SAFETY VALVE.

REMOVING TOOLS FROM THE AIR HOSE

WARNING: ALWAYS SET THE PRESSURE REGULATOR TO ZERO BEFORE YOU REMOVE OR REPLACE A TOOL.

1. Push down on the On/Off button to stop the compressor.

2. Turn the tap handle to the closed position.

3. Operate the tool to depressurise the air hose.

4. Disconnect the tool from the hose

TURNING THE COMPRESSOR OFF

1. Follow steps 1-3 in “Removing Tools From The Air Hose” above.

2. Disconnect the compressor from the power supply.

3. Slowly open the tap to depressurise the reservoir.
   • You will hear a hissing sound as the reservoir depressurises.

4. Do not leave the compressor unattended if the reservoir is pressurised.

DRAINING THE RESERVOIR

CAUTION: YOU MUST DRAIN THE RESERVOIR AFTER EACH DAYS USE AND BEFORE YOU PUT YOUR COMPRESSOR INTO STORAGE.

1. Turn the compressor off and disconnect from the power supply.
2. Put a container below the drain valve to collect the condensate.
   • The drain valve is located on the bottom of the reservoir
3. Open the drain valve slowly.
   • Condensation will drain from the reservoir.
4. Close the drain valve when the reservoir has fully drained.

RESET BUTTON

This compressor has a thermal overload device.

If the motor gets too hot, the thermal overload device cuts the power which prevents damage to the motor.

If the thermal overload device operates, let the motor cool down for 5 minutes and push the reset button.

If you start the compressor and the overload cutout operates again, stop the compressor and disconnect from the power supply and have your compressor examined by a qualified service agent.

MAINTENANCE

WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM THE ELECTRICAL SUPPLY BEFORE CARRYING OUT ANY MAINTENANCE

DRAIN THE RESERVOIR (DAILY)

After use, always open the drain valve to make sure that any condensate is drained off.

CHECK OIL (DAILY)

Ensure the oil level is between the min and max marks on the dipstick. See “Check the Oil level” on page 6 and top-up if necessary – (use Clarke SAE30 compressor oil, available from your local dealer).

CLEAN THE AIR FILTER (MONTHLY)

The air filter must be examined monthly, more often in dusty conditions,

1. Remove the securing bolt and pull the filter from the compressor.

2. Unclip the front and rear of the filter and pull out the filter element.

3. Clean the filter using a soft brush.

   • If necessary, the filter can be carefully cleaned in warm soapy water.
   • Rinse and let the filter dry completely before refitting.
   • If the filter or filter element is damaged, you must replace it.

4. Reassemble the filter and refit it to the compressor using the securing bolt.

REPLACING THE OIL

After the first 100 hours use, replace the oil using Clarke SAE30 compressor oil. Then replace the oil after every 500 hours of operation or every 6 months.

To empty the oil from the machine, remove the oil drain plug from the crankcase.

CHECK THE NON-RETURN VALVE (EVERY 6 MONTHS)

If the reservoir pressure decreases for no apparent reason, it is possible that the non-return valve is leaking. To check this:

1. Make sure that the reservoir is not under pressure and the compressor is switched OFF.

2. . Examine the non-return valve, and replace the gasket and valve if necessary.

REPLACING THE DRIVE BELT

WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM THE ELECTRICAL SUPPLY BEFORE REPLACING THE DRIVE BELT.

1. Rotate the clips on the front of the safety cage.

2. Remove the front of the cage and take out the worn or broken drive belt.

3. Place the new drive belt over the small wheel.

4. Position part of the drive belt over the large belt wheel as shown.

5. Rotate the large belt wheel by hand in a clockwise direction whilst guiding the belt on to it.

   • Take care to avoid trapping your fingers between the wheel and belt.

6. Replace the cage and secure before use.

NOTE: Never use the compressor with the guard removed.

SPECIFICATIONS

MODEL BOXER 14/150

Part Number: 2245210
Max Pressure: 10 Bar
Voltage: 230V AC@50 Hz
Air Displacement: 14 CFM
Receiver Capacity: 150 L
Fuse Rating: 13 A
Dimensions (L x W x H): 1300 x 400 x 790 mm
Guaranteed Sound Power Level: 94 dB(A)
Weight: 75 kg

Please note that the details and specifications contained herein, are correct at
the time of going to print. We reserve the right to change specifications at any time without prior notice.

TROUBLESHOOTING

CAUTION: DO NOT TRY TO REPAIR OR ADJUSTMENT IF YOU ARE UNCERTAIN. IF YOU HAVE ANY QUERIES, CONTACT YOUR CLARKE DEALER

1.    Check electrical connections.
2.    Clean and tighten if necessary.
Overload cutout switch has tripped.| 1.    Switch off and wait approx 5 minutes.
2.    Press the reset button and switch on again.
Motor windings burnt out.| 1. Contact your Clarke dealer for a replacement motor.
The compressor does not reach the set pressure and overheats.| Compressor head gasket blown or valve broken.| 1. Return the machine to your nearest service agent.
Compressor does not start.| The reservoir has already fully pressurised.| 1. Open drain valve to expel air. Compressor should start again when pressure reduces.
Air leaking from the non-return valve when the compressor is not running.| Faulty non-return valve.| 1.    Drain receiver completely of air.
2.    Remove the valve end plug,
3.    Carefully clean the valve seat and the gasket
4.    Reassemble.
Air pressure from the regulator will not adjust.| The diaphragm within the regulator body is broken.| 1.  Replace regulator
The compressor is very noisy and makes a metallic knocking sound.| Compressor damaged and needs overhaul.| 1. Return the machine to your nearest service agent.

EXPLODED DIAGRAM

PARTS LIST

NO| DESCRIPTION| PART NO|  | NO| DESCRIPTION| PART NO
---|---|---|---|---|---|---
1| Crankcase| FN4105267| 112| Nipple| FN4100629
2| Cylinder block| FN4105268| 127| Rilsan Pipe| FN9270006
3| Cylinder Head| FN4105274| 131| Press Switch| FN9063147
4| Crankshaft| FN4105269| 132| Power Cable| FN9065811
5| Lower Cover| FN4105257| 134| Drive pulley|
6| Kit Valve Holder| FN4105293| 135| Motor| FN845S000
8| Conrod| FN4105262| 141| Shroud| FN4105261
12| Piston|  | 142| Belt Guard| FN4101125
14| Gudgeon pin|  | 145| Delivery pipe| FN4101149
15| Circlip|  | 200| Pump assembly| FN41P0019SGL
23| Kit Intake Filter| FN4105290| 300| Feet set| FN41K0174
24| Aftercooler| FN4105283| 408| Air Filter|
26| End Cover| FN4105254| 909| Kit Gaskets| FN4105850
27| Front Support| FN4105253| 912| Kit Piston Ring| FN4105674
29| Flywheel| FN4105228| 920| Piston Kit| FN4105294
30| Bearing| FN9170116|
31| O-ring|
32| Oil seal|
33| Dipstick Assembly| FN4105289
34| Gasket| FN9163010
35| Screw| FN4105231
36| Washer| FN4105234
37| Lower Gasket|
38| Head gasket|
39| Lower gasket|
52| Cold Start Valve| FN4101047
104| Drive Belt|
105| Non Return Valve| FN9048052
106| Outlet Tap| FN9047005
107| Drain Valve| FN9053063
110| Safety valve| FN4101065

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

This is an important document and should be retained.

We. Clarke International, as the authorised representa the of the manufacturer, declare that the following product(s) comply with the directiels) and standards) listed below.

Product Description: Air Compressor
Model number(s): Boxer 14/150 (3HP, IPH, 230V)
Serial / batch Number: 2245210
Notified Body: N/A

Technical Documentation Holder:
A R. Pond
Clarke International
2a Shrubland Road
London E10.7RB
UK

Conformity Assessment Procedure: to 2000/14/EC Annex VI Manufacturer: European Suppler
Noise Related Value: 2 2 kW
Measured Sound Power Level: 91.508
Guaranteed Sound Power Level: 94 dB

Directive(s):
2006/42/EC Machinery Directive.
2000/14/EC Noise Emissions Directive, (amended by 2005/88/EC). 2014/30/EU Electromagnetic Compatibility Directive. 2011/65/EU Restriction of Hazardous substances.

Standard (s):
EN 1012-1, EN 60204-1, EN61000-6-3, EN61000-6-4.

The technical documentation required to demonstrate that the product(s) meet(s) the requirement(s) of the aforementioned directive(s) has been compiled and is available for inspection by the relevant enforcement authorities.

The CE mark was first applied in: 2018

Signed:

Date of Issue:
12/01/2018

Place of issue:
Clarke International
Hemnall Street
Epping Essex, CM16 4LG
England

PARTS & SERVICE:

0208 988 7400

Parts Enquiries

Parts@clarkeinternational.com

Servicing & Technical Enquiries

Service@clarkeinternational.com

SALES: UK 01992 565333 or Export 00 44 (0)1992 565335

Clarke INTERNATIONAL Hemnall Street, Epping, Essex CM16 4LG
www.clarkeinternational.com

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