Clarke BANDIT IV Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1120 - ISS 3
AIR COMPRESSOR
MODEL NO: BANDIT IV
PART NO: 2241000

2
INTRODUCTION
Thank you for purchasing this Air Compressor.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all 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 product giving you long and satisfactory service.
SPECIFICATION
Please note that the details and specifications contained herein, are correct
at the time of going to print.
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 to us without prior permission.
This guarantee does not effect your statutory rights.
Power supply 230 VAC/ 50 Hz
Dimensions (L x W x H) 460 X 225 X 450 mm
Weight 16 kg
Receiver capacity 8L
Fuse rating 13 amps
Max working pressure 8 Bar/116 psi
Max flow rate 4.5 cu.ft/min)
Guaranteed Sound Power Level 94 dB A

3
GENERAL SAFETY WARNINGS
WORK AREA
1. Keep the work area clean and well lit. Floors should always be kept clear.
Cluttered or dark areas invite accidents.
2. Keep children and bystanders away while operating a power tool.
Distractions can cause loss of control.
3. The compressor should only be used in areas with adequate ventilation
and should not be exposed to heat or used near flammable substances
PERSONAL SAFETY
1. ALWAYS stay alert, watch what you are doing and use common sense
when operating the compressor. Do not use the compressor while you are
tired or under the influence of medication, drugs or alcohol. A moment of
inattention can result in personal injury.
2. ALWAYS use eye protection when operating compressed air equipment,
and ensure that others in the work area are protected from flying particles
from the front and from the side.
3. ALWAYS protect yourself against electric shock. Never operate the
compressor in wet or damp locations.
4. NEVER over-reach. Keep your proper footing and balance at all times to
enable better control of the compressor in unexpected situations.
5. NEVER attempt any complex repairs yourself. If you have a technical
problem contact your local dealer.
6. ALWAYS store the compressor out of reach of children.
7. ALWAYS protect your hearing. Ear protection should be worn when
operating this compressor and it’s associated power tools.
8. NEVER direct the air stream at people or animals, as injury may result.
Compressed air can cause soft tissue damage and propel dirt and other
particles at high speed.
9. NEVER insert your fingers or other objects inside the motor housing. Never
operate the compressor without the cover in place.
WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY
WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO
OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.

4
GENERAL MACHINE USE AND CARE
1. Prior to use, all operators should become familiar with the instructions in this
booklet especially the ON/OFF switch for emergency stopping.
2. ALWAYS maintain the compressor with care and keep it clean for best /
safest performance.
3. NEVER use this compressor if any part is damaged. Have it inspected and
repaired by your dealer.
4. NEVER attempt to modify the air compressor, tank, fittings or attachments in
any way. Doing so will invalidate the guarantee and could result in
personal injury.
5. NEVER abuse the power cable. Never pull on the cable when removing the
plug from the socket, or lift the compressor by the power cable.
6. ONLY use extension leads that are of an appropriate power rating and
suitable for the work environment. Extension leads must have an earth
connection. Inspect the extension lead regularly and replace if damaged.
7. ONLY USE RECOMMENDED PARTS: To avoid the risk of bursting, only hoses
with a rated pressure of 10 bar, or more should be used. Never attempt to
repair damaged hoses.
8. NEVER abuse the compressor by standing on it.
AIRLINE HOSES
1. ALWAYS ensure that equipment or power tools used in conjunction with the
compressor have a safe working pressure exceeding that of the machine.
2. ALWAYS keep the air hose away from any attached power tools and
ensure that the operator is not restricted by the length of the hose.
3. ALWAYS take care when a long air hose is required in the work area as it
presents a trip hazard. Coil the hose away as soon as the job is finished.
4. ALWAYS avoid kinking or trapping the air hose. Always replace faulty hoses
and never attempt a repair if a leak is detected.
5. NEVER abuse hoses or connectors. NEVER carry an air tool by the hose, or
yank it to disconnect from the air supply. Keep hoses away from heat, oil
and sharp edges. Check hoses for leaks or worn condition before use and
ensure that all connections are secure.
6. ALWAYS ensure that the air supply is turned off at the machine outlet and
any air pressure vented from within the compressor and any attached
equipment when disconnecting air hoses or other equipment.

5
AIR COMPRESSOR SAFETY INSTRUCTIONS
1. ONLY USE WITHIN THE RECOMMENDED OPERATING TEMPERATURE RANGE:
This compressor should only be used in an ambient temperature of
between +5OC and +40OC (never at or below freezing temperatures).
2. NEVER USE AN AIR COMPRESSOR WHICH APPEARS DEFECTIVE OR IS
OPERATING ABNORMALLY: If the compressor operates unusually or makes
strange noises, switch off immediately and purge the air reservoir. Arrange
repairs with your nearest dealer.
3. BREATHING QUALITY AIR: This compressor should not be used to supply
breathing quality air.
4. SAFETY VALVE: Never remove or attempt to adjust the safety valve. The
maximum pressure is factory set. Keep the safety valve free from paint and
other accumulations.
5. AVOID UNINTENTIONAL STARTING: Do not move the compressor when it is
connected to the mains power supply.
6. BEFORE EACH USE CHECK THE COMPRESSOR AND HOSE FOR DAMAGED
PARTS: Never use the compressor if it has been damaged in any way. Have
the compressor repaired by a qualified service engineer. Do not use the
compressor if the On/Off switch does not operate correctly.
7. KEEP THE MOTOR AIR VENTS CLEAR: Keep the motor vents clear and free
from dust. Wipe regularly to maintain an adequate supply of clean air.
Avoid using in dusty conditions.
8. OPERATE THE COMPRESSOR AT THE CORRECT VOLTAGE: Make sure that the
mains supply voltage is the same as the voltage shown on the label.
9. ALWAYS adjust the pressure regulator to the recommended setting for the
particular spray gun or air tool being used.
10. When using the compressor for painting:
• Do not work in enclosed areas or near naked flames.
• Ensure that the area in which you are working has good ventilation.
• Protect your nose and mouth with a suitable face mask.
• Always check the safety data sheets for substances being sprayed &
ensure manufacturer’s instructions are followed.
11. DO NOT USE THIS COMPRESSOR TO INFLATE SMALL, LOW-PRESSURE OBJECTS:
Items such as children's toys or footballs can explode if over-inflated.
12. NEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF
AT THE MAINS SUPPLY: Always use the On/Off switch on the compressor.

6
SAFETY SYMBOLS
The following safety symbols are shown on the product or it’s packaging.
Please read all of the safety and operating instructions carefully before use.
Read this instruction booklet carefully before positioning,
operating or adjusting the compressor.
This compressor produces a high sound level during operation.
Ear protection should be worn.
This compressor contains surfaces which may get hot during
operation. Never operate with the motor housing removed.
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 receiver is filled with compressed air.
Risk of electric shock. The compressor must be disconnected
from the mains supply before removing any covers. Do not use
in a damp environment.
Wear er protection when using this compressor.

7
ELECTRICAL CONNECTIONS
Before switching the product on, make sure that the voltage of your electricity supply is
the same as that indicated on the rating plate. This product is designed to operate on
230VAC 50Hz. Connecting it to any other power source may cause damage.
This product may be fitted with a non-rewireable plug. If it is necessary to change the
fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or
damaged, the plug must not be used until a suitable replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring instructions
shown below. The old plug must be disposed of safely, as insertion into a mains socket
could cause an electrical hazard.
If the colours of the wires in the power cable of this product do not correspond with the
markings on the terminals of your plug, proceed as follows.
•TheBlue wire must be connected to the terminal marked Nor coloured Black.
•TheBrown wire must be connected to the terminal marked Lor coloured Red.
•TheYellow and Green wire must be connected to the terminal marked E or
or coloured Green.
We strongly recommend that this machine is connected to the mains supply
via a Residual Current Device (RCD). If in any doubt, consult a qualified
electrician. DO NOT attempt any repairs yourself.
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
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
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)
Earth
(Green and Yellow)

8
ASSEMBLY
FIT THE AIR FILTER
1. Remove the travel plug.
2. Screw the air filter into position.
• The air filter must be hand tight
only.
FIT THE OIL FILLER CAP
1. Remove the travel plug.
2. Insert the oil filler cap.

9
MOVING THE AIR COMPRESSOR
• Stop the compressor and disconnect it from the power supply
before you move it.
• Always use the handle.
• To prevent damage, do not lift by (or put strain on) valves or hoses.
BEFORE USE
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. Make sure that the oil level is half
way up the oil sight glass.
2. If not, remove the oil cap and
add oil to the reservoir.
• Only use SAE30 compressor oil,
available from your Clarke
dealer Part No. 3050801
CAUTION: TO PREVENT INJURY, GET ASSISTANCE WHEN LIFTING THIS
COMPRESSOR.

10
CHECK THE SAFETY VALVE
To make sure that the safety valve works correctly:
1. Unscrew the knurled end and pull
it firmly outwards.
• Air will be released when you
pull the cap out 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. Screw the knurled end cap back into position.
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 13
ATTACHING AIR TOOLS
1. Attach the air hose to the ¼" BSP
outlet valve.
2. Attach the tool to the end of the
air hose.
WARNING: DO NOT REMOVE OR TRY TO ADJUST THE SAFETY VALVE.
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.

11
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.
SET THE OUTPUT PRESSURE
1. Use the pressure regulator to set
the output pressure.
• Turn clockwise to increase the
pressure.
• Turn counterclockwise to
decrease the pressure.
GAUGES
1. The reservoir pressure gauge
shows the current pressure in the
reservoir.
2. The outlet pressure gauge shows
the ‘user set’ outlet pressure. This
can be adjusted as shown above.

12
REMOVING TOOLS FROM THE AIR HOSE
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.
WARNING: ALWAYS SET THE PRESSURE REGULATOR TO ZERO BEFORE YOU
REMOVE OR REPLACE A TOOL.

13
DRAINING THE RESERVOIR
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.
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.
CAUTION: YOU MUST DRAIN THE RESERVOIR AFTER EACH DAYS USE AND
BEFORE YOU PUT YOUR COMPRESSOR INTO STORAGE.

14
MAINTENANCE
DRAIN THE RESERVOIR (DAILY)
After use, always open the drain valve to make sure that any condensate is
drained off.
CLEAN THE AIR FILTER (MONTHLY)
The air filter must be examined monthly, more often in dusty conditions,
1. Remove the filter from the
compressor.
2. Remove the filter cover from the
filter.
3. Remove the filter from the filter
cover.
4. Clean the sponge and the filter
cover 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.
5. Make sure that the filter and filter cover are replaced into position.
• If the filter is damaged, you must replace it.

15
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,
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.
CLEANING
Keep the compressor free of dirt and
dust as far as possible. Wipe with a
clean cloth or blow it down with
compressed air at low pressure.
If cleaning is required, use a damp
cloth and some soft soap. Do not use
cleaning agents or solvents as these may be aggressive to the plastic parts.
Always disconnect the hose and any air tools from the compressor before
cleaning.
STORAGE
Disconnect the mains plug and ventilate the compressor and any connected
pneumatic tools. Store the compressor in a dry location. Always store upright.
ENVIRONMENTAL RECYCLING POLICY
By purchasing this product, the customer is taking on the obligation
to comply with current WEEE regulations.
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.
This product contains valuable raw materials. Metal products should be taken
to your local civic amenity site for recycling of metal products.

16
TROUBLESHOOTING
CAUTION: DO NOT TRY TO REPAIR OR ADJUST THIS COMPRESSOR IF YOU
ARE UNCERTAIN OF YOUR ABILITY. IF YOU HAVE ANY QUERIES, CONTACT
YOUR DEALER.
PROBLEM PROBABLE CAUSE REMEDY
The compressor
has stopped
and does not
start.
Bad electrical
connections.
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 dealer for a
replacement motor.
The compressor
does not reach
the set pressure
and overheats
easily.
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 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
Compressor is
noisy & makes a
metallic sound.
Compressor damaged
and needs overhaul.
1. Return the machine to your
nearest service agent.

17
DECLARATION OF CONFORMITY

18
COMPONENT PARTS

19
No Description No Description
1Bolt 34 Bearing
2 Spring Washer 35 Motor Bracket
3 Air Filter 36 Spring Washer
4 Cylinder Head 37 Bolt
5ORing 38 Fan
6 Valve Plate 39 Circlip
7 Valve Slice 40 Fan Cover
8 Valve Gasket 41 Right-Angle Connector
9LocatingPin 42 Bolt
10 Cylinder 43 Fan Cover
11 Bolt 44 Screw
12 Cylinder Gasket 45 Coupler
13 Piston Ring 46 Regulator
14 Oil Scraper Ring 47 Straight Joints
15 Piston 48 Pressure Switch
16 Circlip 49 Safety Valve
17 Connecting Rod 50 Pressure Gauge 40
18 Crankcase 51 Pressure Gauge 50
19 Crank 52 Nut
20 Rubber Gasket 53 Power Cable
21 Breath Pipe 54 One-way Valve
22 O Ring 55 Discharge Pipe
23 Crankcase Cover 56 Release Pipe
24 Screw 57 Handle
25 Oil Sightglass 58 Bolt
26 Piston Pin 59 Nut
27 Nut 60 8L Tank
28 Tooth Washer 61 Nut M5
29 Capacitor 62 Washer Foot
30 Sealing Ring 63 Bolt
31 Bearing 64 Drain Cock 1/4 Inch
32 Rotor 65 Thermal Protector
33 Stator assembly