Clarke Air SP15ND Installation and operation manual

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Operating & Maintenance
Instructions 1110
©
Air Compressor
ENGINE DRIVEN

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INTRODUCTION
Thank you for purchasing this Clarke portable compressor.
The unit is powered by a Honda engine, a manual for which,
is provided separately. Please refer to that manual for all
matters relating to the engine, ...starting and stopping
procedures, maintenance etc.
Read these safety instructions before using the equipment.
GUARANTEE
This product is guaranteed against faults in manufacture for 12 months
from purchase date. Please keep your receipt as proof of purchase.
This guarantee is invalid if the product has been abused or tampered
with in any way, or not used for the purpose for which it is intended.
The reason for return must be clearly stated.
This guarantee does not affect your statutory rights.
SPECIFICATIONS
SP15ND
Part Number 2090575
Engine Type HONDA GX200
Pump Type MK103
Air Receiver size 150 litres
Max. output Pressure 100 psi
Air Displacement 15 cfm
Outlet connectors 1/2”
Dimensions (mm) 1270 x 460 x 870
Weight (kg) 99 kg
Sound Power Level**
** See Declaration of Conformity
NOTE:
Specifications are correct at
the time of going to print.
Clarke International reserves
the right to change
specifications at any time, as
it sees fit, in the interests of
safety or improvement in
design.

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FOR YOUR SAFETY
WARNING
As with all machinery, there are certain hazards involved with their operation and use.
Exercising respect and caution will considerably lessen the risk of personal injury.
However, if normal safety precautions are overlooked, or ignored, personal injury to
the operator, or damage to property may result.
It is in your own interest to read and pay attention to the following rules:
General Precautions
ALWAYS
• ensure that all individuals using the compressor have read and fully understand the
Operating Instructions supplied and are suitably trained
• stop the engine and ensure the pressure is expelled from the air receiver BEFORE carrying
out any maintenance.
• ensure that there is adequate ventilation when spraying flammable materials e.g.
cellulose paint, and keep clear of any possible source of ignition.
• protect yourself. Think carefully about any potential hazards which may be created by using
the air compressor and use the appropriate protection. e.g. Goggles will protect your eyes
from flying particles. Face masks will protect you against paint spray and/or fumes. Ear defenders
will prevent hearing damage caused by load noise.
• consult paint manufacturers instructions for safety and usage, before spraying
• ensure that the air supply is turned off at the machine outlet and all pressurised air from
the machine and other equipment attached to it, is expelled BEFORE disconnecting air
hoses or other equipment.
• make sure that children and animals are kept well away from the compressor and any
equipment attached to it.
• ensure that any equipment or tool used in conjunction with your compressor, has a
safety working pressure exceeding that of the machine.
NEVER
• direct a jet of air at people or animals, and NEVER discharge compressed air against
the skin. COMPRESSED AIR CAN BE DANGEROUS!
• leave pressure in the receiver overnight, or when transporting.
• adjust, or tamper with the safety valves. The maximum pressure is factory set, and clearly
marked on the machine.
• operate in wet or damp conditions. Keep the machine dry at all times. Similarly, a clean
atmosphere will ensure efficient operation. Do not use in dusty or otherwise dirty locations.
• touch the machine until it has cooled down...some of the metal parts can become
quite hot during operation.
• operate your compressor with any guards removed.

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]
Fire Prevention
ALWAYS
•switch the engine OFF when refuelling.
•refuel away from any source of heat.
•refuel in a well ventilated area.
NEVER
•overfill the tank, fill to the level specified.
•smoke whilst refuelling and avoid smoking or using a naked flame near the compressor.
•start the engine if there is spilled fuel. Any spillage must be wiped clean and the
compressor allowed to dry before attempting to start the engine.
IMPORTANT General Notes
• NEVER allow anyone, not fully familiar with compressors, to use this equipment.
• DO NOT alter the engine settings....these settings are set at the factory. Should they
need recalibration - consult your Clarke dealer
Exhaust Gas Precautions
WARNING:
Exhaust fumes can be fatal
ALWAYS
• ensure there is adequate ventilation when using the compressor.
• position the compressor so that the exhaust is pointed away from people or animals
.
WARNING!
DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS
DOING SO WILL INVALIDATE YOUR GUARANTEE
NEVER
• use the compressor indoors or in an enclosed area. (i.e. in a warehouse, tunnel, well,
hold etc.)

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Fig.1

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PREPARATION FOR USE
A. Environmental
• Ensure the compressor is sited on a firm level surface.
• Ensure the environment is dry and dust free.
• Ensure there is adequate ventilation for:
a) Air intake to compressor pump
b) Cooling for compressor pump
c) Engine exhaust gases.
B. Engine
Check oil and fuel levels and a visual check of components. Refer to engine service manual.
C. Pump
• Check oil level on the Dipstick - to level marked.
D. Fuelling
Fill with unleaded petrol, according to the instructions within the engine manual.
• Ensure the fuel tap is set to the required position.
• Ensure The fuel hose and connectors are intact, in perfectly serviceable
condition and there is no leakage.
Note : Always use a funnel to fill the fuel tank so as to avoid accidental spillage of
fuel. If fuel is spilled it must be removed from the unit and surrounding area, before
attempting to start the engine.
E. Receiver
• Drain off any condensate, by opening the drain cock (see Fig. 1). Remember
to close the drain cock when completed.
NOTE: This should be carried out DAILY when the compressor is in constant use.
F. Air Hose & Air Tool
• Attach the air hose to the outlet using an appropriate connector.
• Attach the air tool/spray gun to the air hose...If using snap couplings, use
a whip end, available from your Clarke dealer.
]

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STARTING THE COMPRESSOR
1. Open the drain cock and allow any condensate to drain compleatly,
• The drain cock in located on the bottom of the receiver tank.
2. Close the drain cock.
3. Fully open the bleed valve.
4. Connect the air hose to the air outlet. connect your air tool to the air hose.
• Ensure the air outlet tap is closed.
5. Start the engine, according to the instructions contained in the engine service
manual, if this is the first time you use the compressor, allow to run for 10 minutes.
6. Close the bleed valve fully.
• Pressure will build up in the receiver and eventually the air governor will
operate so that the engine runs off load.
• The pressure registered on the pressure gauge should be 100psi.
7. Use you air tool as indicated in its user guide
• Observe the pressure gauge. When the pressure has dropped by approx.
20psi, the Air Governor/Load Genie will operate and the compressor will
cut in again.
Fig.2
STOPPING THE COMPRESSOR
1. At the end of the day, stop the compressor in accordance with the
engine manual.
2. Operate the air tool trigger or operating lever etc., to ensure there is no
pressure in the air line, then disconnect airline and tool.
WARNING!
DO NOT under any circumstances attempt to remove the air tool or disconnect
the air hose until you are satisfied that the pressure has been relieved.
3. Finally, open the drain cock very slowly to release the pressure in the tank.
Take care not to touch the engine or pump as they remain hot for some time
after use.

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MAINTENANCE
DAILY
a. Drain Air Receiver of any condensate
b. Check engine oil level and top up where necessary. Ensure the dipstick
breather hole is not blocked.
c. Check pump oil level
WEEKLY
a. Clean Pump Air Filter
Unbolt the Pump Air Filter cover and pull away to reveal foam element.
If badly contaminated, replace. Remove any loose contaminants if any
then replace.
b. Clean the engine cooling fins.
6 MONTHLY
Renew pump lubricating oil.
Drain pump by removing the drain
screw (Arrowed in Fig.3).
Replace screw and top up until oil is
level with the mark on the dipstick,
using SAE40 oil available from your
Clarke dealer as follows:
Compressor oil - 1 litre: Part No. 3050810
Compressor oil - 5 litre: Part No. 3050802
Repairs should only be carried out by a qualified engineer. If problems
occur, contact your Clarke dealer.
In addition to the above, check the engine manual for service
schedule.
Fig.3

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PUMP PARTS

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PUMP PARTS
1 Screw
2 Lower Cover
3 Casing
4 Bearing
5 Seal
6 Front Cover
7 Screw
8 Flywheel
9 Washer
10 Screw
11 Screw
12 Washer
13 Rear Cover
14 Oil Dipstick
15 Screw
16 Crankshaft
17 Connecting Rod
18 Piston Ring Kit
19 Circlip
20 Gudgeon Pin
21 Piston
22 Complete Piston
23 Cylinder
24 Valve Holder Plate
25 Head
26 Filter Cartridge
27 Intake Filter
28 Screw
29 Conveyor
30 Screw
31 Complete Seal Kit
32 Manifold
33 Automatic Discharge Valve
15ND
014013054
113149015
113167001
033027000
010053000
113149008
014013021
013160010
014005001
113160011
014013082
014005025
113149009
012036000
014010044
113167003
113150004
213167001
015023000
116025006
113164009
413167006
113167002
413167005
113150022
017003000
317001000
014002041
113150002
014006121
213167002
116091024
011158000
No. Description Part No.

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PARTS LIST
HS17210-ZE1-822
HS17218-ZE1-821
HS98079-56846
1. HS28442-ZH8-003
2. HS28442-ZH8-003
3. HS28462-ZH8-003
50mm Pressure Gauge 2000161
Safety Valve Complete 2000192
Drain Cock 2000220
V-Belt 2000078
Pump Complete. 1390085 (MK103)
Pulley 2100084
Engine complete 8000055 (GX200QH)
Manifold 3-way CBM45469000
Air Receiver 1985150
2100177

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TROUBLE SHOOTING CHART
IMPORTANT
1. Any remedial work that may be required must be carried out by a qualified engineer.
2. Switch off the engine before removing any parts from the compressor.
3. Drain the Air Receiver before dismantling any part of the compressor unit’s pressure system.
4. If your compressor develops a fault do not use until the fault has been rectified.
5. For troubleshooting the engine, refer to the engine manual.
REMEDY
Stop engine and empty air
receiver. Clean or replace
Load Genie
Thaw Load Genie out (Unit must
be installed in frost-free place).
Have Load Genie serviced or
replaced
Contact Clarke Service
Department
Contact Clarke Service
Department
SYMPTOM
Engine difficult to
start
PROBABLE CAUSE
Load Genie leaking
(compressor unit is on load
during start).
Load Genie valve blocked,
possibly frozen up.
Compressor unit
constantly ‘on load’
Load Genie defective.
Load Genie set at a pressure
higher than the safety
valve’s opening pressure.
Load Genie leaking.
Compressor constantly
‘on load’ and cannot
attain the working
pressure required.
Suction filter blocked.
Leak between compressor
block and air receiver leaks in
or near air receiver.
Valves blocked by dirt, paint,
dust or choked up.
Inspection cover or drain plug
leaking.
Clean / Change filter.
Tighten connection and
repair leak.
Contact Clarke Service
Department
Empty air receiver and
change seals/plugs.
Pressure gauge defective.
Unit too small in relation to
air consumption.
Change pressure gauge.
Use a larger capacity
compressor
Compressor worn. Have compressor overhauled or
replace it.

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Unusual noise from
compressor. Bolts loose.
Flywheel loose.
Unit installed on an unsuitable
base.
Bearings, piston rings or cylinder
worn.
Valve broken.
Compressor
becomes too hot.
Contact Clarke Service
Department
Insufficient ventilation.
Oil level too low (check 2 or 3
times after stopping).
Fault in valves (machine not
stopping).
Not fully unloading
Load genie partly blocked.
Clean cooling fins and suction
filter.
Blown head gasket (machine
not stopping).
Dirt on cooling fins or suction
filter.
Unit working at too high a
pressure.
Contact Clarke Service
Department
Contact Clarke Service
Department
Contact Clarke Service
Department
Connect to a supplementary
compressor or install a larger
model.
See that sufficient air is supplied to
flywheel or fan of compressor and
that hot air is properly vented.
Fill with oil – see Page 10.
Tighten bolts - see page 16.
Tighten flywheel.
Move unit to a more solid base.
Contact Clarke Service
Department
Contact Clarke Service
Department
Compressor being
overworked and running
continuously.
Contact Clarke Service
Department

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Large amount of condensation in
air receiver.
Leaks in system
Compressor unit runs
on and off load more
frequently than usual.
Compressor unit runs
‘on load’ when no air is
being used.
Leaks in system.
Compressor’s oil
consumption rising.
Too much oil in compressor.
Cylinder worn.
Oil in the air delivered.
Oil level rises although
no oil has been put in.
Piping installation incorrect.
Compressor taking in air which is
too warm.
Condensation at outlet
points.
Drain off condensation Regularly
(Every day before use).
Locate leaks (by means of soapy
water) and repair.
Locate leaks (by means of
soapy water) and repair.
Intake air filter blocked.
Sump over full.
Leaks around crank case.
Working temperature of
compressor too high because of
insufficient cooling.
Cylinder worn.
Check oil level 2 or 3 minutes after
stopping.
Contact Clarke Service
Department
Increase ventilation to air
compressor.
Reduce oil to correct level.
Compressor over dimensioned.
Intake air filter blocked.
Condensation in oil pump.
Consult your local dealer.
Obtain better fresh-air supply to
compressor.
Clean or replace
Contact Clarke Service
Department
Contact Clarke Service
Department
Clean / Change air filter.
REBMUNLEDOM eluaVeuqroT
)MN(
DN51PS 6.12-6.02
Torque values for cylinder head bolts

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Notes