Clarke BOXER II 14 50L BELT Driven Air Compressor Instruction Manual

Clarke BOXER II 14 50L BELT Driven Air Compressor

INTRODUCTION
Thank you for purchasing this CLARKE Air Compressor.
Before attempting to operate the machine, it is essential that you read this manual thoroughly and follow all instructions given. This will ensure the safety of yourself and others and you can look forward to the product giving you long and satisfactory service.

GUARANTEE

This CLARKE 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 to us without prior permission. This guarantee does not effect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY
By purchasing this product, the customer is taking on the obligation to deal with its safe disposal in accordance with the Waste Electrical and Electronic Equipment (WEEE) regulations. In effect, this means that this product must not be disposed of with general household waste but according to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal facility.
If disposing of this product or any damaged components, do not dispose of with general waste. This product contains valuable raw materials. Metal products should be taken to your local civic amenity site for recycling of metal products.

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 any 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. These compressors produce noise levels in excess of 70dB(A). Persons working near the compressor must be supplied with ear protection.

SAFETY SYMBOLS

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

• 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 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.

ASSEMBLY

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

ATTACH THE WHEELS

1. Slide the axle through the wheel and hole in the wheel frame.
2. Lock the wheel in place using the washer and nut provided.
3. Fit the cap into the position shown.

ATTACH THE SUPPORT FEET
Insert the support feet into the position shown.

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:-

• Push down the OFF button.
• Remove the protective plastic molding from the top of the cylinder head.
• 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 ISO100 (SAE30) compressor oil, available from your CLARKE dealer Part No. 3050796.
   • Take care not to to fill above 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.

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. Attach the air hose to the outlet valve.
2. Attach the air tool to the other end of the air hose.
3. Turn the outlet valve handle to the on position.
   NOTE: The outlet valve 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.

CHECKING THE SAFETY VALVE
To make sure that the safety valve works correctly.

1. Unscrew and pull on the knurled part of the safety valve.
   • Air will be released when you pull hard on the valev end 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.
3. Once tested, screw the knurled part back in.

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

SETTING THE OUTLET PRESSURE

1. Use the pressure regulator to set the outlet pressure.
   • Turn clockwise to increase the pressure.
   • Turn counterclockwise to decrease the pressure.

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 outlet valve handle to the off 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 outlet valve 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.
3. Open the drain valve slowly.
   • Condensation will drain from the reservoir.
4. Close the drain valve when the reservoir has fully drained.

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

CHECK THE OIL
Ensure the oil level is between the min and max marks on the dipstick. See “Check the Oil level” on page 7 and top-up if necessary – (use SAE30 compressor oil available from your CLARKE dealer).

CLEAN THE AIR FILTER
The air filter must be examined monthly or 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.

CHECKING THE NON-RETURN VALVE
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 remove the damaged drive belt.
3. Pass the new drive belt over the small pulley first.
4. Pass the belt over the large pulley.
5. Rotate the large pulley by hand in a clockwise direction whilst guiding the belt on to it.
   • Take care to avoid trapping your fingers between the pulley and belt.
6. Replace the cage and secure before use.

WARNING: NEVER USE THE COMPRESSOR WITH THE GUARD REMOVED.

SPECIFICATIONS

MODEL                                                   BOXER II 14/50P
Part Number                                              2245312
Motor Size                                                 3 HP
Voltage                                                       230 VAC (50Hz)
Air Displacement                                        384 L/min (14 cfm)
Max Pressure                                              10 Bar (145 psi)
Receiver Capacity                                        50 L
Ingress Protection                                       IP20
Fuse Rating                                                  13 A
Duty cycle                                                    S3/50%
Oil requirements                                          ISO100 (SAE30) compressor oil
Oil capacity                                                  0.4L
Dimensions (L x W x H)                              800 x 350 x 670 mm
Guaranteed Sound Power Level                   97 dB(A)
Weight                                                          60 kg

TROUBLESHOOTING

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

COMPONENT PARTS

PARTS LIST

1. CRANKCASE
2. CYLINDER
3. CYLINDER HEAD
4. CRANKSHAFT
5. LOWER COVER
6. VALVE HOLDER ASSEMBLY
7. GASKET
8. CONROD
9. INTAKE FILTER ASSEMBLY
10. AIR COOLER
11. CYLINDER HEAD BOLT
12. END COVER
13. O-RING
14. BEARING 6205 XL
15. OIL SEAL D3760
16. O-RING
17. BEARING RETAINER
18. FLYWHEEL
19. DIPSTICK ASSEMBLY
20. SCREW M8X25 8.8 LEFT (GB5781)
21. WASHER 9.2X36X4
22. COLD START VALVE R1/4X2.2BAR
23. SHROUD
24. GASKETS SET 213167002
25. PISTON RING SET
26. PISTON ASSEMBLY
27. n/a
28. NON RETURN VALVE
29. TAP BALL VALVE
30. DRAIN.VALVE 3/8
31. PRESSURE REGULATOR
32. GAUGE 50mm 10BAR
33. GAUGE 40mm
34. SAFETY VALVE 10BAR
35. CONNECTOR 199021000
36. RILSAN PIPE 4/6 BLACK
37. PRESSURE SWITCH
38. POWER CABLE
39. MOTOR 540E150605
40. BELT GUARD
41. DRIVE PULLEY
42. DRIVE BELT
43. AIR PIPE
44. PUMP ASSEMBLY COMPLETE
45. WHEEL KIT COMPLETE

Parts & Service: 020 8988 7400
E-mail: Parts@clarkeinternational.com
Service@clarkeinternational.com

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