Clarke BOXER 100 Instruction Manual

1
OPERATION & MAINTENANCE
INSTRUCTIONS ©
BOXER 100
AIR COMPRESSOR
0109
BOXER 100
AIR COMPRESSOR

2
Thank you for purchasing this Clarke BOXER 100 Air Compressor which is fitted
with a 100 litre air reservoir.
Please read this leaflet thoroughly and carefully follow all instructions. In doing
so you will ensure the safety of yourself and that of others around you, and you
can look forward to the compressor giving you long and satisfactory service.
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.
CONTENTS PAGE
SafetyPrecautions ........................................................................... 3
Warning Symbols ............................................................................. 7
Electrical Connections...................................................................... 8
Parts Identification............................................................................ 9
Assembly.......................................................................................... 10
Preparation for use........................................................................... 12
Operating instructions ...................................................................... 13
RoutineMaintenance ....................................................................... 16
Troubleshooting ............................................................................... 19
Specifications ................................................................................... 20
Parts Diagram .................................................................................. 21
Parts List .......................................................................................... 22
Declaration of Conformity................................................................. 23

3
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:
WARNING!
When using the air compressor, you should follow basic safety precautions
including the following to reduce the risk of personal injury. Make sure that
you have read all of the instructions before using the air compressor. Keep
this booklet with the compressor for future reference by the operator. Persons
who have not read this booklet should not use the air compressor.
WARNING!
Compressed air can be dangerous. Death or serious injury could result from
improper or unsafe use of this compressor. To avoid these risks, use your
common sense and follow these basic safety instructions. Compressed air
should never be inhaled as it may contain toxic vapours or solid particles.
Always work in good ventilation, especially when spraying paints or other
toxic substances and always use a suitable face mask. Do not spray near
sources of possible ignition.
WARNING!
Attachments, hoses and accessories must meet or exceed the maximum
pressure rating of this compressor.
If low pressure parts are used, the air pressure could cause them to explode
or fly apart, resulting in serious injury. Always take great care when releasing
the pressure and connecting/disconnecting tools.
WARNING!
This compressor must be connected to a power socket that is safeguarded
by a suitable circuit breaker or fuse.
SAFETY PRECAUTIONS

4
TRAINING: Prior to use all operators should become familiar with the instructions in this
booklet. In particular, become familiar with the ON/OFF control for emergency stopping.
ALWAYS USE EYE PROTECTION: When operating the air compressor, always use eye
protection, and make sure that other people in the work area are also using eye
protection. Eye protectors must provide protection from flying particles both from the
front and from the side.
NEVER TOUCH MOVING PARTS: Never place your hand near any moving parts on the air
compressor or operate with the covers removed.
PROTECT YOUR SELF AGAINST ELECTRIC SHOCK: Never operate the air compressor in wet
or damp locations.
DRESS PROPERLY: Loose clothing or jewellery may be caught in moving parts. Always tie
long hair back.
KEEP VISITORS/CHILDREN AWAY: Do not allow visitors/children to handle the air compressor
or attachments and ensure that any people in the work area are suitably dressed.
KEEP THE WORK AREA CLEAN: Cluttered areas invite accidents, clear the work area of all
unnecessary tools, debris and furniture.
DISCONNECT THE AIR COMPRESSOR: Always disconnect the air compressor from the mains
power supply and decompress before performing maintenance, changing any parts
and when not in use.
DO NOT ABUSE THE CABLE: Never pull on the cable when removing the plug from the
mains socket, or lift the compressor by the mains cable.
BREATHING QUALITY AIR: This compressor should not be used to supply breathing quality
air.
DO NOT ABUSE THE COMPRESSOR: Do not stand on the compressor.
SAFETY VALVE: Never remove or attempt to adjust the safety valve. Keep the safety valve
free from paint and other accumulations.
AVOID UNINTENTIONAL STARTING: Do not move the air compressor when it is connected
to the mains power supply. When connecting the air compressor to the mains supply
make sure the red button on top of the air compressor is in the OFF (down) position.
STORE THE AIR COMPRESSOR PROPERLY: When not in use the air compressor should be
stored in a secure, dry place out of the reach of children. Always lock up the storage
area.
PROTECT YOUR HEARING: Ear protection should be worn when operating this compressor.
MAINTAIN THE AIR COMPRESSOR WITH CARE: If the air compressor is damaged in any way,
have it repaired by a qualified service engineer.
EXTENSION LEAD: 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.
SAFETY PRECAUTIONS

5
ONLY USE PARTS AND ACCESSORIES RECOMMENDED IN THIS MANUAL: The use of
unauthorised accessories or attachments is not permitted and may result in personal
injury and damage to the air compressor. Do not attempt to repair or modify the air
compressor.
STAY ALERT: Watch what you are doing, use common sense, and do not operate the air
compressor when you are tired. The air compressor should not be used if you are under
the influence of alcohol, drugs or any medication that makes you drowsy.
BEFORE EACH USE CHECK THE AIR COMPRESSOR AND HOSE FOR DAMAGED PARTS: Never
use the air compressor if it has been damaged in any way. Have the air compressor
repaired by a qualified service engineer. Do not use the air compressor if the On/Off
switch does not operate correctly.
HANDLE THE AIR COMPRESSOR CAREFULLY: Operate the air compressor according to the
instructions contained within this instruction booklet. This air compressor should never be
operated by children or individuals unfamiliar with its operation.
KEEP THE MOTOR AIR VENT CLEAR: Keep the motor vent clear and free from dust, wipe
regularly to maintain an adequate supply of clean air to the air compressor.
OPERATE THE AIR COMPRESSOR AT THE CORRECT VOLTAGE: Make sure that the mains
supply voltage is the same as the voltage shown on the rating plate.
DO NOT WIPE THE PLASTIC PARTS WITH SOLVENT: Do not use solvents or thinners such as
petrol, benzene, carbon tetrachloride or alcohol to clean the air compressor, as these
chemicals will damage the finish. With the air compressor unplugged from the supply, use
a dry cloth to wipe over the plastic casing.
KEEP ALL SCREWS AND COVERS TIGHTLY IN PLACE: Check the screws and covers
periodically.
ADEQUATE VENTILATION: The compressor should only be used in areas with adequate
ventilation and should not be exposed to heat, or used near inflammable substances.
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 tank. Arrange repair with an authorised service centre.
DO NOT MODIFY THE AIR COMPRESSOR: Do not 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.
DO NOT MODIFY THE TANK: Do not modify the tank or operate at pressures or
temperatures outside the limits stated in this booklet.
TURN OFF THE AIR COMPRESSOR WHEN NOT IN USE: When not in use, turn off the air
compressor by pressing the On/Off switch, remove the plug from the mains supply and
slowly undo the drain valve to release the pressure from the tank. Remember to close the
drain valve before storage and ensure it is fully tightened before use.
DO NOT TOUCH HOT SURFACES: During operation, the motor, connections, compressor
body, cylinder head and tubes may get hot, please take care.
SAFETY PRECAUTIONS

6
DO NOT DIRECT THE AIR STREAM AT THE BODY: Do not 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.
ONLY USE RECOMMENDED PARTS: To avoid the risk of bursting, only hoses with a rated
pressure of 8 bar, or more should be used. Never attempt to repair faulty hoses.
DO NOT USE THIS COMPRESSOR TO INFLATE SMALL, LOW-PRESSURE OBJECTS: Items such as
children's toys or footballs can explode if over-inflated.
AVOID KINKING OR TRAPPING THE AIR HOSE: Always replace faulty hoses - never attempt
a repair if a leak is detected.
DRAIN TANK: Drain the tank after each use. Switch off and slowly open the drain valve to
release the air then tilt the compressor to empty condensed water.
NEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF AT THE MAINS
SUPPLY: Always use the On/Off switch on the compressor.
NEVER OPERATE WITHOUT ALL GUARDS IN PLACE: Never operate without all guards or
safety features in place and in proper working order.
NEVER OPERATE IN THE PRESENCE OF FLAMMABLE LIQUIDS OR GASES: The air compressor
produces sparks during operation.
CHECK FOR DAMAGED PARTS AND AIR LEAKS: If any part of the compressor is damaged, it
should be carefully checked to determine that it will operate correctly and perform its
intended function. Check for the alignment of parts, damage to parts, air leaks and any
other conditions that may affect its operation. A guard or any other part that is damaged
or defective should be properly repaired or replaced by an authorised service centre.
Defective pressure switches must be replaced prior to further use of the compressor.
ONLY USE WITHIN THE RECOMMENDED OPERATING TEMPERATURE RANGE: This compressor
should only be used in an ambient temperature of between 0OC and 25OC.
CLEANING AND CONDITION OF THE COMPRESSOR: Keep the external surfaces of the tank
clean. Avoid impact damage and do not allow the tank to come into contact with
abrasive or corrosive materials.
MOVING THE COMPRESSOR: Always transport the compressor by lifting or pulling it with the
appropriate grips or handles.
USING THE COMPRESSOR FOR PAINTING:
• Do not work in enclosed areas or near naked flames.
• Make sure 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
manufacturers instructions are followed.
MOTOR HOUSING: Do not insert your fingers or other objects inside the motor housing to
avoid physical damage or damage to the compressor.
SAFETY PRECAUTIONS

7
WARNING SYMBOLS
READ THIS INSTRUCTION BOOKLET CAREFULLY BEFORE
POSITIONING, OPERATING OR ADJUSTING THE
COMPRESSOR.
Risk of electric shock. The compressor must be disconnected
from the mains supply before removing any covers. Do not
use in a damp environment.
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 tank is filled with compressed air.
This compressor contains surfaces which may reach a high
temperature during operation. Never operate with the motor
housing removed.
Air and condensation water can burst from the compressor
when the drain plug is removed.
Wear a safety goggles and ear protectors when using this
compressor
This compressor produces a high sound level during
operation. Ear protection should be worn.

8
ELECTRICAL CONNECTIONS
Connect the mains lead to a 230Volt (50Hz) single phase 30 amp electrical supply,
through a suitably fused isolator with a fuse rating of 20 Amps.
DO NOT connect to a domestic system via a 13 AMP plug.
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:
•The wire which is coloured green and yellow must be connected to the
terminal which is marked with the letter E or by the earth Symbol ( ) or
coloured green or green and yellow.
•The wire which is coloured blue must be connected to the terminal which is
marked with the letter N or coloured black.
•The wire which is coloured brown must be connected to the terminal which is
marked with the letter L or coloured red.
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 local Clarke dealer or Clarke International on:
020 8988 7400 or e-mail [e-mail]

9
PARTS IDENTIFICATION
1
7
89
10
11
12 6
1 Reset Button
2 On/Off switch (red button)
3 Reservoir pressure gauge
4 Output pressure regulator
5 Output pressure gauge
6 Handle
7 Support foot
8 Drain valve
9 Compressed air reservoir
10 Transportation wheel
11 Data Plate
12 Pressure regulator and cut-out
13 Oil level indicator
14 Outlet tap
13
24
3
15
5
15

10
ASSEMBLY
WARNING!
Before assembling and using the air compressor, make sure that you have
read and understood all of the safety instructions.
Installation
Take care when lifting the compressor from the packaging.
CAUTION! Do not lift the compressor by the Pressure regulator and cut-out. Get
assistance if necessary. This unit weighs 71kg.
After removing the compressor from its packaging, make sure it has not been
damaged in transit.
Positioning the air compressor
This compressor should be positioned on a
stable, flat surface (or one with a maximum
inclination of 15O), See figure 1, and ensure
it is completely stable.
Do not cover or box in the compressor.
Always position it at least 50cm from any
obstacle or wall
Make sure the compressor has good all
round ventilation.
Figure 1
12345678901234567890123
1
234567890123456789012
3
12345678901234567890123
150
max

11
Figure 2
ASSEMBLY
Moving the air compressor
Before moving the compressor, switch off and disconnect it from the mains
power supply.
• Always use the handle.
• Do not lift by (or put strain on) fittings, valves or hoses.
• Take care when moving the compressor to avoid damaging the valves or
fittings.
The compressor is heavy, get assistance when lifting and moving this compressor
to avoid personal injury.
PREPARING FOR USE
Before connecting your compressor to the mains supply,
Check the Oil
1. Make sure that the oil level is within the small
circle on the oil level indicator. See figure 2.
• If needed top up the reservoir with Clarke
SAE 30 compressor oil, available from your
Clarke dealer. OIL Level
Indicator

12
PREPARING FOR USE
Before connecting your compressor to the mains supply, check the following:-
• The mains voltage is 230V.
• The ON/OFF switch is in the OFF (lower) position.
• The pressure regulator should be set at its lowest setting, i.e. turned fully
anticlockwise.
• If the compressor has not been used for 24 hours or so, open the drain
valve to drain any condensate which may have accumulated. When
clear, close the drain valve, finger tight.
IMPORTANT: If the air reservoir is under pressure, keep your hands well
away from the air being expelled.... remember, compressed air is
DANGEROUS!
WARNING!
Before connecting any air tool, make sure you have read and fully
understood the manufacturers instruction booklet for the tool being used.
Also ensure that the tool is compatible with the compressor and hose
specifications.
The pressure regulator must be used to adjust the output pressure.
1 Ensure that the red On/Off switch is set to
the OFF position (pressed down). See
figure 4.
2. Insert the mains plug into the mains socket
and switch on the power.
3. Pull up the red ON/OFF switch up and run
the compressor (with the outlet tap open)
for 10 to 15 seconds, to allow the
distribution of the lubricating oil.
4 Attach the air hose to one of the outlet
taps using the hose nuts. See figure 5.
Figure 5
Figure 4
On/Off Switch
Hose Nut
Hose Nut

13
OPERATING INSTRUCTIONS
Switching the air compressor ON
The compressor will make a continuous loud noise when the tank is charging -
this is normal.
1 Lift the red On/Off switch located on top of the pressure regulator and cut-
out.
• The compressor will charge the main tank to 10 bar (145 psi) then switch
off.
• The compressor will restart automatically whenever the pressure in the
main tank falls below a certain level.
2 Check the operation of the safety
valve, under pressure, daily by pulling
the ring as shown in figure 6. Air should
be released you pull the ring and stop
when the ring is released.
• If the valve does not operate as
described, or if the valve is stuck, it
must be replaced by qualified
service personnel before using the
compressor.
WARNING!
Do not remove or attempt to adjust the safety valve.
3 Select the pressure you need using
the pressure regulator. See figure 7.
4 Open the outlet tap.
Figure 7
Figure 6
Pressure
regulator
Output pressure
gauge
Outlet
Tap

14
OPERATING INSTRUCTIONS
Switching the air compressor off
To switch the air compressor off,
1. Close the outlet tap and press down on the on/off button (red button)
located on top of the pressure regulator and cut-out.
2. Switch off the mains supply and remove the plug.
• You should never leave the compressor air tank unattended while
under pressure.
• Always release the pressure from the tank when not in use or prior to
storage, as described in 'Draining the reservoir' on page 15.
Removing a tool from the air hose
WARNING!
Always set the pressure regulator to zero before attempting to remove or
replace a tool.
1 Stop the power supply by pressing down on the on/off button (red button)
located on top of the pressure regulator and cut-out.
2 Close the air outlet tap and trigger the equipment (spraygun, air tool etc),
to release air from the air hose BEFORE disconnecting the hose from the
machine.
Reset button
This compressor is equipped with a thermal
overload device, which operates as a
safety device to protect the motor.
When the motor overheats for any reason,
the overload cutout automatically cuts the
power thereby preventing damage to the
motor.
Wait around 5 minutes for the motor to cool
and press the reset button. See figure 8.
If you restart the compressor and the
overload cutout activates again, switch off
the compressor, remove the plug from the
mains and have you compressor checked
by a qualified service agent.
Figure 8

15
Draining the reservoir
CAUTION! It is important to drain the reservoir before storage.
1 Pressing the red On/Off button down to switch the air compressor off and
remove the plug from the mains supply.
• Place a suitable container beneath the compressor to catch any
condensation.
2 Carefully undo the drain valve anticlockwise until you hear a hissing noise,
this is the reservoir depressurising. See figure 9.
• When the reservoir pressure gauge indicates zero and the hissing has
stopped, tighten the drain valve again.
OPERATING INSTRUCTIONS
Figure 9
Drain valve

16
Figure 10
ROUTINE MAINTENANCE
IMPORTANT: Before carrying out any maintainance work, always
disconnect the compressor from the mains supply, drain the air receiver
and, if necessary, allow the machine to cool down before starting work.
Daily
Check Oil
Ensure the oil level is between the min and max marks on the dipstick. See page
12 and top-up if necessary - (use Clarke SAE 30 compressor oil, available from
your local dealer).
Drain the tank
After use, always open the drain valve to ensure that any liquid that may have
condensed, is drained off. See page 15.
Monthly
The air intake filter should be inspected on a MONTHLY basis, and more often in
dusty conditions,
To clean the air intake filter,
1 Pull the filter cover away from the
compressor as shown. See figure 10.
2 Remove the sponge filter from the
filter cover. See figure 11.
3 Clean the sponge and the filter
cover using a soft brush.
• If necessary, the sponge filter may
be gently washed in warm soapy
water,
• Rinse and allow the filter to dry
thoroughly before refitting.
5 Ensure that the filter and filter cover is
then placed back into its original
position.
• If any part of the filter is
damaged, you should obtain a
replacement.
Figure 11

17
ROUTINE MAINTENANCE
Every six months
Make sure that all bolts are securely tightened.
Clean all the external parts of the
compressor.
Oil
After the first 100 hours use, replace the
oil completely 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 cover.
Non Return Valve
Examine the non-return valve, and
replace the gasket and valve if
necessary
Figure 12
Figure 13
Figure 14

18
ROUTINE MAINTENANCE
Replacing the drive belt
1 Rotate the clips on the front of the
safety cage. Remove the front of
the cage and take out the worn
or broken drive belt.
2. Place the replacement drive belt
over the small wheel. See figure
16.
3. Position part of the drive belt over
the large belt wheel as shown in
figure 17.
4. Rotate the large belt wheel by
hand in a anticlockwise direction
whilst guiding the belt on to the
belt wheel.
Figure 16
Figure 17
Figure 15

19
TROUBLE SHOOTING
With considerate use, your Clarke BOXER 100 Air Compressor should provide you
with long and trouble free service. Routine checks should be made on both the
electrical supply as well as on all the compressed air lines and connections. If
any fault appears, the reason for which is not immediately obvious, we
recommend that you contact your local Clarke dealer.
CAUTION Do not attempt any repair or adjustment if you are uncertain as
to how it should be done. If you have any queries, contact your local
Clarke Dealer.
tluaF esuaC ydemeR
rosserpmocehT
seoddnadeppots
.tratston
.snoitcennocdaB
hctiwstuotucdaolrevO
ytudrodeppirtsah
neebsahelcyc
.dedeecxe
tnrubsgnidniwrotoM
.tuo
lacirtcelekcehC
dnanaelC.snoitcennoc
.yrassecensanethgit
tiawdnaffohctiwS
erofebsetunim5xorppa
nottubteserehtgnisserp
.niaganognihctiwsdna
ekralClacolruoytcatnoC
tnemecalperarofrelaed
.rotom
rosserpmocehT
hcaertonseod
erusserpteseht
staehrevodna
.ylisae
daehrosserpmoC
evlavronwolbteksag
.nekorb
otrosserpmocroftiaW
elbmessasid,nwodlooc
ynaecalperdnadaeh
.stnenopmocnekorb
gnilaesllanaelcylluferaC
erofebsecafrus
tbuodnifI.gnilbmessaer
ekralCruoytcatnoc
.relaed
seodrosserpmoC
.tratston
degrahcreviecerriA lepxeotevlavniardnepO
dluohsrosserpmoC.ria
erusserpnehwniagatrats
.isp59.xorppaotsecuder
morfgnikaelriA
erusserpeht
nehwevlavhctiws
sirosserpmoceht
.gninnurton
.evlavnruter-nonytluaF reviecerniardtsriF
evomeR.riafoyletelpmoc
,gulpdneevlaveht
evlavehtnaelcylluferac
dnateksagehtdnataes
.41erugiFeeS.elbmessaer
morferusserpriA
lliwrotalugereht
.tsujdaton
nihtiwmgarhpaidehT
siydobrotalugereht
.nekorb
rotalugerecalpeR
sirosserpmocehT
dnaysionyrev
cillatemasekam
.dnuosgnikconk
degamadrosserpmoC
.luahrevosdeendna
otenihcamehtnruteR
ecivrestseraenruoy
.tnega

20
SPECIFICATIONS
Electrical Supply ..................................... 230 V, 1 Phase 50Hz
Max. Operating Pressure ....................... 10 bar / 145 psi
Motor Rating ........................................... 3 HP
Air Displacement .................................... 12.2 cuft/min
Air Receiver............................................. 100 litre
Net Weight .............................................. 71kg
Dimensions ( L x W x H ) ......................... 1220 x 460 x 810 mm
Duty Cycle .............................................. S1 (continuous)
Part No. .................................................... 2225460
Please note that the details and specifications contained herein, are correct at
the time of going to print. However, we reserve the right to change
specifications at any time without prior notice. Always consult the machine’s
data plate