Clarke Air XP15 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS1019 - ISS 2
ORIGINAL INSTRUCTIONS
150L ENGINE DRIVEN AIR COMPRESSOR
MODEL NO: XP15
PART NO: 2092500

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INTRODUCTION
Thank you for purchasing this CLARKE compressor which is designed to supply
compressed air to air powered tools for a wide range of applications such as
spraying, sanding, drilling, and cutting.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safe operation
of the compressor.
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.
RESIDUAL RISK
Although this manual contains extensive safety warnings and information on
the safe operation of your compressor, every tool does have certain residual
risks which cannot be completely excluded with warnings or safety devices.
This compressor must therefore always be operated with caution.
NOISE LEVELS
This machine produces noise levels in excess of 70dB(A). Persons working in the
vicinity of the machine must be provided with suitable ear protection.

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SPECIFICATIONS
NOTE: Specifications are correct at the time of going to print. In the
interests of safety or improvement in design, Clarke International
reserves the right to change specifications at any time.
Part Number 2092500
Engine Type Honda GP200H
Pump Type NH3AP
Air Receiver Size 150 l
Maximum Outpur Pressure 100 psi
Air Displacement CFM 15
Outlet Connections 1/2”
Dimensions (mm L X W X H 1330 x 420 x 850
Weight (kg) 88
WARNING: DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS, DOING
SO WILL INVALIDATE YOUR GUARANTEE

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FOR YOUR SAFETY
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.
DO NOT
• Direct a jet of air at people or animals, and NEVER discharge
compressed air against the skin. Compressed air CAN BE dangerous!
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:

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• 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.
FIRE PREVENTION
ALWAYS
• Switch the engine OFF when refuelling.
• Refuel away from any source of heat.
• Refuel in a well ventilated area.
DO NOT
• 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.
EXHAUST GAS PRECAUTIONS
ALWAYS
• Make sure that there is adequate ventilation when using the
compressor.
• Position the compressor so that the exhaust is pointed away from people
or animals.
DO NOT
• Use the compressor indoors or in an enclosed area. (i.e. in a warehouse,
tunnel, well, hold etc.)
WARNING: EXHAUST FUMES CAN BE FATAL

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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 re-calibration - consult your Clarke dealer
OVERVIEW

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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 sightglass - 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. At the beginning of the day, open the drain cock and allow any
condensate to drain completely, then close the drain cock.
2. To ease starting, ensure there is
no pressure in the pump outlet
manifold by opening the Bleed
valve.
3. Connect the air hose to the air
outlet.
4. Connect your air tool to the air
hose.
• Make sure that the air outlet
tap is closed
5. Start the engine in accordance with the instructions contained in the
engine service manual, If this is the first time you are using the compressor,
allow it 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 guage should be 100psi.
7. Use your air tool as prescribed in its user guide.
• When the pressure has dropped by approximatley 20psi the compressor
will start up again.

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STOPPING THE COMPRESSOR
1. At the end of the day, stop the compressor in accordance with the
instructions in 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.
3. Finally, close the drain cock very slowly to release pressure in the tank..
4. Take care not to touch the engine or pump as they remain hot for some
time after use.
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.

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MAINTENANCE
DAILY
1. Drain Air Receiver of any condensate
2. Check engine oil level and top up where necessary. Ensure the dipstick
breather hole is not blocked.
3. Check pump oil level
WEEKLY
1. 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.
2. Clean the engine cooling fins.
6 MONTHLY
1. Renew pump lubricating oil.
2. Drain pump by removing the
drain screw.
3. Replace screw and top up the oil
to the level on the sightglass. Use
SAE40 oil available from your
Clarke dealer as follows:
• Compressor oil - 1 litre: Part No.
3050810
• Compressor oil - 5 litre: Part No.
3050802
In addition to the above, check the
engine manual for service schedule.
Repairs should only be carried out by a qualified engineer. If problems occur,
contact your Clarke dealer.

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TROUBLESHOOTING CHART
IMPORTANT!
1. Any remedial work that may be required must be carried out by a qualified
electrician/engineer.
2. Empty Air Receiver of Air before dismantling any part of the compressor
unit’s pressure system.
3. If your compressor develops a fault do not use until the fault has been
rectified.
SYMPTOM PROBABLE CAUSE REMEDY
Engine
difficult to
start
Load Genie leaking
(compressor unit is on load
during start).
Stop engine and empty air
receiver. Clean or replace
Load Genie
Load Genie valve blocked,
possibly frozen up.
Thaw Load Genie out (Unit
must be installed in frost-
free place).
Compressor
unit
constantly ‘on
load’
Load Genie defective Have Load Genie serviced
or replaced
Load Genie set at a pressure
higher than the safety valve’s
opening pressure
Contact Clarke Service
Department
Load Genie leaking. Contact Clarke Service
Department
Unusual noise
from
compressor.
Bolts loose. Tighten bolts
Flywheel loose. Tighten flywheel
Unit installed on an unsuitable
base.
Move unit to a more solid
base
Bearings, piston rings or
cylinder worn.
Contact Clarke Service
Department
Valve broken Contact Clarke Service
Department

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
Compressor
constantly ‘on
load’ and
cannot attain
the working
pressure
required.
Suction filter blocked. Clean / Change filter.
Leak between compressor
block and air receiver leaks in
or near air receiver.
Tighten connection and
repair leak.
Valves blocked by dirt, paint,
dust or choked up.
Contact Clarke Service
Department
Inspection cover or drain plug
leaking.
Empty air receiver and
change seals/plugs.
Pressure gauge defective Change pressure gauge.
Unit too small in relation to air
consumption.
Use a larger capacity
compressor
Compressor worn. Have compressor
overhauled or replace it.
Compressor
becomes too
hot.
Insufficient ventilation. See that sufficient air is
supplied to flywheel or fan
of compressor and that
hot air is properly vented.
Oil level too low (check 2 or
3 minutes after stopping.
Fill with oil
Fault in valves (machine not
stopping).
Contact Clarke Service
Department
Blown head gasket (machine
not stopping).
Contact Clarke Service
Department
Dirt on cooling fins or suction
filter.
Clean cooling fins and
suction filter.
Unit working at too high a
pressure.
Contact Clarke Service
Department
Not fully unloading Contact Clarke Service
Department
Load genie partly blocked. Contact Clarke Service
Department
SYMPTOM PROBABLE CAUSE REMEDY

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

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PUMP EXPLODED DIAGRAM

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PUMP PARTS LIST
NO DESCRIPTION PART NO NO DESCRIPTION PART NO
1 HEX SCREW HS2065Z01 27 CYLINDER GASKET HS2065Z27
2 SPRING WASHER HS2065Z02 28 CYLINDER HS2065Z28
3 FRONT COVER HS2065Z03 29 VALVE PLATE GASKET HS2065Z29
4FRONTCOVER
GASKET
HS2065Z04 30 VALVE PLATE HS2065Z30
5 BALL BEARING HS2065Z05 31 ALUMINUM GASKET HS2065Z31
6 OIL SIGHTGLASS HS2065Z06 32 VALVE REED HS2065Z32
7 OIL SIGHTGLASS
SEAL
HS2065Z07 33 VALVE PLATE HS2065Z33
8 BREATHER
(M16*1.5)
HS2065Z08 34 HEAD COVER GASKET HS2065Z34
9 CRANKCASE HS2065Z09 35 AIR FILTER HS2065Z35
10 BASEPLATE SEAL HS2065Z10 36 HEX SCREW HS2065Z36
11 BASEPLATE HS2065Z11 37 HEX SCREW HS2065Z37
12 SPRING WASHER HS2065Z12 38 SPRING WASHER HS2065Z38
13 HEX SCREW HS2065Z13 39 HEAD COVER HS2065Z39
14 OIL PLUG (G1/8") HS2065Z14 40 AFTERCOOLER GASKET HS2065Z40
15 CRANKSHAFT HS2065Z15 41 AFTERCOOLER HS2065Z41
16 BALL BEARING HS2065Z16 42 SPRING WASHER HS2065Z42
17 BEARING SEAT
GASKET
HS2065Z17 43 HEX SCREW HS2065Z43
18 OIL SEAL HS2065Z18 44 CONNECTOR HS2065Z44
19 BEARING SEAT HS2065Z19 45 CONNECTOR NUT HS2065Z45
20 SPRING WASHER HS2065Z20 46 PISTON PIN HS2065Z46
21 HEX SCREW HS2065Z21 47 COMPRESSOR RING HS2065Z47
22 FLYWHEEL HS2065Z22 48 OIL RING HS2065Z48
23 FLYWHEEL FLAT
WASHER
HS2065Z23 49 PIN CLIP HS2065Z49
24 FLYWHEEL SCREW HS2065Z24 50 PISTON HS2065Z50
25 HEX SCREW HS2065Z25 51 CONNECTING ROD HS2065Z51
26 SPRING WASHER HS2065Z26