Clarke AIR PIONEER 100 Manual

0104
PIONEER 100
AIR COMPRESSOR
PIONEER 100
AIR COMPRESSOR
OPERATING & MAINTENANCE
INSTRUCTIONS

2
SPECIFICATIONS
Rotational Speed...................................................2850 rpm
Max. Pressure ......................................................... 8 bar (116psi)
Air Displacement ................................................... 100Ltrs/min
Electric Motor ......................................................... 0.65HP (0.48HP)
Receiver ................................................................. 10 Ltr
Compressor Oil ......................................................CLARKE SAE 40
Fuse Rating 230V ..................................................13amps
110V ..................................................16A
Gross Weight ..........................................................25.5kgs
Part Number 230V .................................................2320033
110V ..................................................2320035
Duty Cycle .............................................................S1* at 7bar
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
*The compressor may be run continuously at an output pressure of 7bar
15
PARTS DIAGRAM
RECEIVER ASSY

3
Thank you for purchasing this Pioneer Air Compressor which is fitted with a 10litre
air receiver.
Before attempting to operate the machine, please read this leaflet thoroughly
and carefully follow the instructions given. In doing so you will ensure the safety
of yourself and that of others around you, and you can also look forward to the
compressor giving you long and satisfactory service.
CONTENTS Page
Specifications .................................................................................. 2
Safety Precautions .......................................................................... 4
Electrical Connections ................................................................... 5
Assembly .......................................................................................... 6
Preparation for Use ......................................................................... 6
Operation ........................................................................................ 7
Shutting Down ................................................................................. 8
Maintenance .................................................................................. 9
Accessories .................................................................................... 11
Parts & service Contacts .............................................................. 10
Parts List and Diagrams ......................................................... 11 - 15
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.
No. Description Qty Part No
SPARE PARTS
14
50 Tank ....................................................................... 1 ....... FN164A51000V
51 Wheel .................................................................... 2 ....... FN020006000
52 Circlip .................................................................... 2 ....... FN015018000
53 Drain Cock ........................................................... 1 ....... FN022020000
54 Foot........................................................................ 2 ....... FN116011006
55 Plug ........................................................................ 2 ....... FN011008000
56 Vibration Damper ................................................ 4 ....... FN199575000
57 Handle................................................................... 2 ....... FN116022015
58 Non Return Valve ................................................. 1 ....... FN347043000
59 Gasket ................................................................... 1 ....... FN010041000
60 Spring .................................................................... 1 ....... FN047113002
61 Seal ........................................................................ 1 ....... FN047129001
62 Elbow ..................................................................... 1 ....... FN011055000
63 Rilsan Tube ............................................................ 1 ....... FN046001000
64 Delivery Tube ........................................................ 1 ....... FN101GE0011
65 Elbow ..................................................................... 1 ....... FN011015000
66 Nipple .................................................................... 1 ....... FN199110140
67 Power Cord With Plug 240V ............................... 1 ....... FN101GA0200
67 Power Cord 110V................................................. 1 ....... FN165E03200
68 Pressure Switch ..................................................... 1 ....... FN321028000
69 Nipple .................................................................... 1 ....... FN011017000
70 Pressure Reducer ................................................. 1 ....... FN319100000
71 Line Cock.............................................................. 1 ....... FNA04093100
72 Slotted Nut ............................................................ 1 ....... FN116011065
73 Pressure Gauge ................................................... 1 ....... FN330006000
74 Pressure Gauge ................................................... 1 ....... FN330004000
75 Relief Valve .......................................................... 1 ....... FN047205000

SAFETY PRECAUTIONS
WARNING!
Compressed air can be dangerous.
Follow these safety instructions carefully.
•NEVER direct a jet of compressed air at people or animals, or spray
paint towards people or animals.
ALWAYS use appropriate protective equipment, such as Clarke safety-
compressed air tools.
• Air compressors work at high pressure. ALWAYS inspect equipment and hoses
before use, checking for any damage or leaks. Have any damage properly
repaired before using the machine again.
•DO NOT operate the compressor with any guards removed.
•DO NOT adjust or tamper with the safety valve in any way. The maximum
working pressure is clearly marked on the compressor.
• The compressor will become hot during operation. DO NOT touch the
•ALWAYS release any pressure from the air hose (by operating the tool briefly)
before disconnecting any hoses or tools.
•ALWAYS ensure the pressure is expelled from the air receiver, and the machine
is disconnected from the mains supply, BEFORE carrying out any maintenance,
•DO NOT leave pressure in the receiver overnight, or when transporting.
•DO NOT adjust, or tamper with the safety valves. The maximum pressure is
factory set, and clearly marked on the machine.
•ENSURE that any equipment or tool used in conjunction with your compressor,
has a safety working pressure exceeding that of the machine.
•ALWAYS consult paint manufacturers instructions, for safety and usage.before
spraying any material
•ALWAYS ensure that all individuals using the compressor have read and fully
understand the Operating Instructions supplied.
When paint spraying:
•ALWAYS wear a suitably approved breathing mask when paint 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 the
paint manufacturers instructions.
• Make sure there is adequate ventilation. DO NOT spray in confined or enclosed
areas.
• Many paints are flammable. DO NOT smoke while spraying or preparing paints,
or spray near a naked flame or heat source.
- 4 - 13
PARTS DIAGRAM
COMPRESSOR ASSY.

5
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 approved to BS1362.
We recommend that this machine is connected to the mains supply via a Residual
Current Device (RCD)
If in any doubt, DO NOT attempt any connections or repairs yourself. Consult a
qualified electrician, your Clarke dealer, or CLARKE International Service Dep’t on
020 8988 7400 or e-mail: [email protected]
PIONEER 110 Volt model
Connect the mains lead to a suitable 110V (50Hz) electrical supply through an
approved plug or a suitably fused isolator switch.
If using a portable 110V transformer, make sure it has a rated capacity sufficient
to take a 13 amp load.
12
SPARE PARTS
No. Description Qty Part No
1 Screw ....................................................................... 4 ...........FN014002026
2 Head ....................................................................... 1 ...........FN116034010
3 Intake Filter ............................................................. 1 ...........FN317007000
4 Head Gasket .......................................................... 1 ........... FN116011037
5 Valve Holder Plate ................................................. 1 ...........FN116034100
6 Cylinder Gasket ..................................................... 1 ...........FN113113034
7 Cylinder................................................................... 1 ...........FN116034006
8 Screw ....................................................................... 2 ...........FN014011064
9 O-Ring ..................................................................... 1 ...........FN010114000
10 Piston Ring Set ........................................................1 ...........FN216011003
11 Piston ....................................................................... 1 ...........FN116011027
12 Circlip ...................................................................... 2 ...........FN015001000
13 Gudgeon Pin .......................................................... 1 ...........FN113113003
14 Complete Piston .................................................... 1 ...........FN416011027
15 Connecting Rod .................................................... 1 ...........FN116091021
16 Oil Dipstick .............................................................. 1 ...........FN012036000
17 Complete Casing Cover ...................................... 1 ...........FN116032014
18 Cover Gasket ......................................................... 1 ...........FN116001025
19 Crankshaft .............................................................. 1 ...........FN116034004
20 Casing ..................................................................... 1 ........... FN116022051
21 Screw ....................................................................... 2 ...........FN116011038
22 Overload Reset 240V ............................................ 1 ...........FN008035000
22 Overload Reset 110V ............................................ 1 ...........FN008015000
23 Capacitor 240V ..................................................... 1 ...........FN009200014
23 Capacitor 110V ..................................................... 1 ...........FN009200026
24 Bearing .................................................................... 1 ...........FN033018000
25 Rotor ........................................................................ 1 ...........FN034045000
26 Stator 240V ............................................................. 1 ...........FN416035605
26 Stator 110V ............................................................. 1 ...........FN416085601
27 Bearing .................................................................... 1 ...........FN033118000
28 Rear Cover ............................................................. 1 ........... FN116011002
29 Fan ........................................................................... 1 ........... FN116001003
30 Housing ................................................................... 1 ...........FN199100070
31 Set Of Gaskets .......................................................1 ...........FN216GE0101

6
ASSEMBLY
1. Remove the plastic travel plug from the oil filling hole (fig.1) and insert the
dipstick (fig.2)
2. Remove the plastic dust cap from the hole in the side of the head, (fig 3), and
squirt a few drops of commonly available light oil (3 in 1 or similar), into the
cylinder head.
3. Screw on the air intake filter (fig.4)
Fig.2
Fig. 1
Fig.4
Fig.3
PREPARATION FOR USE
Check the oil level is at the correct level on the
dipstick, as shown in Fig.5. Where necessary, top up
with Clarke SAE40 Compressor Oil available from your
Clarke dealer.
Fig.5
PARTS LISTS
AND
DIAGRAMS
11

OPERATION
1. Check that the mains voltage corresponds with that shown on the data sticker
on the crankcase cover of the machine.
2. Ensure that the ON/OFF knob on the Pressure Switch is pushed DOWN in the
‘OFF’ (O) position and then switch on at the mains supply.
3. To start the compressor pull the ON/OFF knob, UPWARDS to the ‘ON’ (l) position.
7
NOTE:
Should the motor fail to start
immediately it is probable that
the air receiver is already full of
air. Open the Air Outlet tap, and
trigger the air tool if fited, to
release air and the motor will
start automatically when the
tank pressure is reduced.
4. Before starting any work
allow the compressor to run
with the air outle cock
completely opened, to
permit a good distribution of
the lubricating oil.
5. Close the outlet tap.
6. Connect the air hose and
spraygun, or other air tool,
to the compressor outlet,
preferably using Quick Fit
couplings, readily available
from your Clarke dealer, then re-open the outlet tap.
6. Set the operating pressure by adjusting the pressure regulator. To do this, turn
the knob - clockwise to increase pressure and anti- clockwise to reduce it.
NOTE:
For normal spraying do not exceed 50 psi (unless following paint manufacturer’s
instructions). If other attachments are used, for example a tyre inflating gauge,
staple gun, paraffin gun etc, it may be necessary to set the operating pressure at
a higher (or lower) level. Please refer to the accessory manufacturers’
recommendations for optimum operating pressures for their equipment.
Fig. 6
10
SPARES AND SERVICING
For Spare Parts and/or Servicing, please contact your nearest dealer, or
CLARKE International as follows:
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
ACCESSORIES
Your Clarke Pioneer Air Compressor can be used in conjunction with a range of
optional accessories for inflating tyres, air brushing, stapling, blowing and many
other uses. For details contact your local accessory stockist.
A complete kit - Model KIT 1000, illustrated below, is available from your Clarke
dealer which is ideal for almost all applications.
Please quote part number 3110155
A similar kit is available, without the spray gun - Model KIT 600, Part No. 3110150
The accessories are also available separately
Should you experience any difficulties obtaining accessories, please contact the
Clarke sales department (telephone [phone]) for details of your nearest dealer.

7. The Pressure Switch should not require adjustment. This is an automatic device
and has been pre-set at the factory to stop the motor when the pressure in
the receiver reaches its maximum (115 psi), and to start it again when the
pressure in the receiver falls to the minimum precept value. This operation is
completely automatic and does not affect the spraying process in any way.
NOTE:
If the machine pumps continuously without cutting-out then the compressor
is too small for the application/tool being used, and damage to the
machine may result.
8
1. Press the ON/OFF switch to the off ‘O’ position.
NEVER USE THE MAINS SWITCH TO STOP THE MOTOR.
2. IMPORTANT!...... ALWAYS depress equipment trigger (spraygun) to release air
from the hose and compressor BEFORE disconnecting from the machine.
3. Switch off and disconnect from the mains supply.
SHUTTING DOWN THE COMPRESSOR
MAINTENANCE
Fig. 9
3. After the first 50 hours use, replace the
oil completely (use Clarke SAE 40
compressor oil) and then, after every 100
hours. To empty the oil from the
machine, remove the screw on the front
of the crankcase cover (fig.7).
4. Every 50 hours use, remove the black
plastic air filter (fig.8), then unclip the
back cover.
Remove the filter and wash it in clean
soapy water. Allow to dry completely
before reassembling. Renew the filter if
it is badly contaminated or damaged in
any way.
5) At least once a week drain the
condensate from the receiver by
unscrewing the drain plug underneath
the air receiver (fig.9).
NOTE: If the compressor is used on a daily
basis, then the tank should be drained before
each use.
6) In the event of an air leak follow the
procedure below:
• Load compressor to maximum pressure
• Unplug the compressor
• With a brush and soapy water wet all
‘screwed’ connections
• Any leaks will show through the
formation of air bubbles
NEVER UNSCREW A CONNECTION WHILE THE
RECEIVER TANK IS UNDER PRESSURE...ALWAYS
MAKE CERTAIN THAT THE TANK HAS FIRST
BEEN EMPTIED.
1. After the first 5 hours of running the compressor, check the cylinder head bolts
and motor housing, screws and re-tighten if any have worked loose.
2. Check the oil level every time you start working and top-up if necessary (use
Clarke SAE 40 compressor oil). Fig. 7
Fig.8
9