Clarke Boxer 14/200 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0413
200L BELT DRIVEN AIR COMPRESSOR
MODEL NO: BOXER 14/200
PART NO: 2245215

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INTRODUCTION
Thank you for purchasing this CLARKE 200L Belt Driven Air Compressor.
Read this manual fully before use and follow the instructions carefully. In doing
so you will ensure the safety of yourself and those around you, and you can
look forward to your purchase 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 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.
PARTS AND SERVICING
For Parts & Servicing, please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [e-mail]

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SAFETY PRECAUTIONS
Before using your compressor it is in your own interest to read and pay attention
to the following safety rules.
1. Compressed air is dangerous. Do not point a jet of air at persons or animals, and do
not discharge compressed air against the skin.
2. DO NOT operate your compressor with the guard removed.
3. Repairs must only be carried out by a qualified engineer. If problems occur, contact
your Clarke dealer.
4. Before carrying out any maintenance, make sure that the pressure is released from
the air reservoir, and that the compressor is disconnected from the electrical supply.
5. DO NOT leave pressure in the receiver overnight, or when transporting.
6. DO NOT adjust, or tamper with the safety valves. The maximum pressure is factory
set, and clearly marked on the compressor.
7. DO NOT operate in wet or damp conditions. Keep the compressor dry at all times.
Similarly, clean air will allow the compressor to work efficiently. Do not use in dusty or
otherwise dirty locations.
8. Some of the metal parts can become quite hot during operation. Do not touch/
remove these until the compressor has cooled down.
9. Always set the pressure regulator to the recommended setting for the tool.
10. When spraying flammable materials e.g. cellulose paint, ensure that there is
sufficient airflow and keep clear of any source of ignition.
11. Before spraying any material always consult paint manufacturers instructions for
safety and usage.
12. Protect yourself. Goggles will protect your eyes from flying particles. Face masks will
protect you against paint spray and fumes.
13. Do not apply strain to electrical cables and make sure that air hoses are not kinked
or wrapped around the compressor.
14. When disconnecting air hoses or other equipment from your compressor, make sure
that the air supply is turned off at the outlet and vent all pressurised air from within
the reservoir and other equipment attached to it.
15. Make sure that children and animals are kept well away from the compressor and
any equipment attached to it.
16. Make sure that all individuals using the compressor have had the necessary training
and have read and fully understand these operating instructions.
17. Make sure that any equipment or tool used in conjunction with your compressor, has
a safe working pressure exceeding that of the compressor.
18. Be careful when transporting the compressor to prevent tipping over
19. Permanently installed systems must be installed by a competent engineer.
20. These compressors produce noise levels in excess of 70dB(A). Persons working near
the compressor must be supplied with ear protection.

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SAFETY 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 move 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.
Wear safety goggles and ear protectors when using this
compressor
This compressor produces a high sound level during
operation. Ear protection should be worn.

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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.
If the plug has to be changed because it is not suitable for your socket, or because of
damage, it must be removed and a replacement fitted, following the wiring instructions
shown below. The old plug must be discarded safely, as insertion into a power socket
could cause an electrical hazard.
If the colours of the wires in the power cable do not agree with the markings on the
plug.
• The BLUE wire must be
connected to the
terminal which is marked
N or coloured black.
•TheBROWNwiremustbe
connected to the
terminal which is marked
L or coloured red.
• The YELLOW AND GREEN
wire must be connected
to the terminal which is
marked E or or
coloured green.
We strongly recommend that this machine is connected to the mains supply through a
Residual Current Device (RCD)
If you are not sure, consult a qualified electrician. DO NOT try to do any repairs.
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
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
Earth
(Green and
a 13 Amp
the cable is firmly held by the clamp
fuse.
Yellow)

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BEFORE USE
CAUTION: TO PREVENT INJURY, GET ASSISTANCE WHEN LIFTING OR
MOVING THIS COMPRESSOR.
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. Remove the dipstick from the oil
reservoir.
2. Ensure the oil level is between the
min and max marks on the
dipstick.
• Only use SAE30 compressor oil,
available from your Clarke
dealer Part No. 3050801
• Take care not to exceed the
maximum mark.

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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 10.
MOVING THE AIR COMPRESSOR
• Stop the compressor and disconnect it from the power supply
before you move it.
• Always use the handle.
• Do not lift by (or put strain on) valves or hoses.
ATTACHING AIR TOOLS
1. Attach the air hose to the outlet
valve.
2. Attach the air tool to the other
end of the air hose.
3. Turn the outlet valve handle to the
on position.
NOTE: The outlet valve is shown
without the air hose fitted for
clarity.
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.

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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.
CHECK THE SAFETY VALVE
To make sure that the safety valve works correctly.
1. Pull on the ring attached.
• Air will be released when you
pull on the ring 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.
SET THE OUTLET PRESSURE
1. Use the pressure regulator to set
the outlet pressure.
• Turn clockwise to increase the
pressure.
• Turn counterclockwise to
decrease the pressure.
WARNING: DO NOT REMOVE OR TRY TO ADJUST THE SAFETY VALVE.

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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.

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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.

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MAINTENANCE
DRAIN THE RESERVOIR (DAILY)
After use, always open the drain valve to make sure that any condensate is
drained off.
CHECK OIL (DAILY)
Ensure the oil level is between the min and max marks on the dipstick. See
“Check the Oil level” on page 6 and top-up if necessary - (use Clarke SAE30
compressor oil, available from your local dealer).
CLEAN THE AIR FILTER (MONTHLY)
The air filter must be examined monthly, more often in dusty conditions,
1. Remove the securing bolt and pull
the filter from the compressor
2. Unclip the front and rear of the
filter and pull out the filter
element.
3. Clean the filter 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.
• If the filter or filter element is damaged, you must replace it.
4. Reassemble the filter and refit it to the compressor using the securing bolt.
WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM
THE ELECTRICAL SUPPLY BEFORE CARRYING OUT ANY MAINTENANCE

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REPLACING THE OIL
After the first 100 hours use, replace
the oil 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.
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 checkthis,:
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.

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REPLACING THE DRIVE BELT
1. Rotate the clips on the front of the
safety cage.
2. Remove the front of the cage
and take out the worn or broken
drive belt.
3. Place the new drive belt over the
small pulley.
4. Position part of the drive belt over
the large pulley as shown.
5. Rotate the large pulley by hand in
a clockwise direction whilst
guiding the belt on to it.
• Take care to avoid trapping
your fingers between the pulley
and belt.
6. Replace the cage and secure
before use.
NOTE: Never use the compressor with the guard removed.
WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM
THE ELECTRICAL SUPPLY BEFORE REPLACING THE DRIVE BELT.

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SPECIFICATIONS
MODEL BOXER 14/200
Part Number 2245215
Max Pressure 10 Bar
Vol tage 230 VAC (50/60Hz)
Air Displacement 14 CFM
Receiver Capacity 200 L
Fuse Rating 13 A
Dimensions (L x W x H) 1450 x 440 x 850 mm
Guaranteed Sound Power Level 94 dB(A)
Weight 90 kg
Please note that the details and specifications contained herein, are correct at
the time of going to print. We reserve the right to change specifications at any
time without prior notice.

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TROUBLESHOOTING
CAUTION: DO NOT TRY TO REPAIR OR ADJUSTMENT IF YOU ARE
UNCERTAIN. IF YOU HAVE ANY QUERIES, CONTACT YOUR CLARKE
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 Clarke 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 the 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
The compressor is
very noisy and
makes a metallic
knocking sound.
Compressor damaged and
needs overhaul.
1. Return the machine to your
nearest service agent.

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EXPLODED DIAGRAM

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PARTS LIST
NO DESCRIPTION PART NO
1CRANKCASE
MK102,MK103
FN4105267
2CYLINDER MK103 FN4105268
3HEAD MK103 FN4105274
4CRANKSHAFT
MK102,MK103
FN4105269
5LOWER COVER
MK102,MK103
FN4105257
6KIT VALVE HOLDER
MK103
FN4105293
8CONROD
MK102,MK103
FN4105262
23 KIT INTAKE FILTER
MK103
FN4105290
24 AFTERCOOLER FINAL
MK103
FN4105283
26 END COVER MK102 FN4105254
27 FRONT SUPPORT
MK102
FN4105253
29 FLYWHEEL F251.4-A-
F19.8 SKM12
FN4105228
30 BEARING 6205 XL FN9170116
33 DIPSTICK ASSEMBLY
MK102
FN4105289
34 GASKET ANGUS 35 X
25 X 7 D3760
FN9163010
35 SCREW M8X25 8.8
LEFT (GB5781)
FN4105231
36 WASHER 9.2X36X4 FN4105234
52 COLD START VALVE
R1/4X2.2BAR
FN4101047
141 SHROUD
MK102,MK103
FN4105261
909 KIT GASKETS MK103
213167002
FN4105850
912 KIT PISTON RING
MK103-113
FN4105674
920 PISTON KIT MK103 FN4105294
105 NON RETURN VALVE
MM 1/2X1/2
FN4101056
106 BALL COKC1/2" MF FN9047005
107 DRAIN COCK .G3/8
2000/
FN4100822
109 GAUGE .50 POST.1/4
0/20 11B
FN9052056
110 SAFETY VALVE G1/4
T11 PED
FN4101065
112 NIPPLE DELIVERY
PIPE
FN4100629
127 RILSAN PIPE 4/6
BLACK
FN9270046
131 PRESS.SW .4V 3/
8"12B-4/6,3A
FN9063147
132 CORD 3X1,5X1850
UK
FN9065811
135 MOT.HP3 M90L
230400 S3-75
FN845S000
142 BELT GUARD FN9416978
145 DELIVERY PIPE
MK103/100 B510N
FN9043561
200 PUMP MK103 (1) FN41P0019
SGL
300 KIT FEET FNM (X4) FN41K0174
NO DESCRIPTION PART NO

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY