Clarke Boxer 55 Installation and operation manual

OPERATION & MAINTENANCE

INSTRUCTIONS ©

BOXER 55

AIR COMPRESSOR

0408

BOXER 55

AIR COMPRESSOR

2

Thank you for purchasing this Clarke Boxer 55 Air Compressor which is fitted

with a 50 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.

GUARANTEEGUARANTEE

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.

When disposing of this productWhen disposing of this product

When disposing of this product, ensure it is disposed of according to all local ordinances, ensure it is disposed of according to all local ordinances

, ensure it is disposed of according to all local ordinances, ensure it is disposed of according to all local ordinances

, ensure it is disposed of according to all local ordinances. It must. It must

. It must. It must

. It must

not be disposed of with general household waste.not be disposed of with general household waste.

not be disposed of with general household waste.

3

CONTENTSCONTENTS

CONTENTS PAGEPAGE

PAGEPAGE

PAGE

Safety Precautions ......................................................................... 4

Warning Symbols............................................................................ 9

Electrical Connections .................................................................. 10

Parts Identification ......................................................................... 11

Assembly ......................................................................................... 12

Preparation for use ........................................................................ 14

Operating instructions ................................................................... 15

Routine Maintenance ................................................................... 19

Troubleshooting.............................................................................. 22

Specifications ................................................................................. 23

Parts Diagram ................................................................................. 24

Parts List ........................................................................................... 25

Declaration of Conformity` ........................................................... 26

4

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

WARNINGWARNING

WARNING

As with all machinerAs with all machiner

As with all machineryy

yy

y, there are cer, there are cer

, there are cer, there are cer

, there are certain hazards involved with theirtain hazards involved with their

tain hazards involved with theirtain hazards involved with their

tain hazards involved with their

operation and use. Exercising respect and caution will considerablyoperation and use. Exercising respect and caution will considerably

operation and use. Exercising respect and caution will considerably

lessen the risk of personal injurlessen the risk of personal injur

lessen the risk of personal injuryy

yy

y. However. However

. However. However

. However, if normal safety, if normal safety

, if normal safety, if normal safety

, if normal safety

precautions are overlooked, or ignored, personal injury to theprecautions are overlooked, or ignored, personal injury to the

precautions are overlooked, or ignored, personal injury to the

operatoroperator

operator, or damage to proper, or damage to proper

, or damage to proper, or damage to proper

, or damage to property may result. It is in your own interestty may result. It is in your own interest

ty may result. It is in your own interestty may result. It is in your own interest

ty may result. It is in your own interest

to read and pay attention to the following rules:to read and pay attention to the following rules:

to read and pay attention to the following rules:

WARNING!WARNING!

WARNING!

When using the air compressorWhen using the air compressor

When using the air compressor, you should follow basic safety, you should follow basic safety

, you should follow basic safety, you should follow basic safety

, you should follow basic safety

precautions including the following to reduce the risk of personalprecautions including the following to reduce the risk of personal

precautions including the following to reduce the risk of personal

injurinjur

injuryy

yy

y. Mak. Mak

. Mak. Mak

. Make sure that you have read all of the instructions beforee sure that you have read all of the instructions before

e sure that you have read all of the instructions beforee sure that you have read all of the instructions before

e sure that you have read all of the instructions before

using the air compressorusing the air compressor

using the air compressor. Keep this booklet with the compressor for. Keep this booklet with the compressor for

. Keep this booklet with the compressor for. Keep this booklet with the compressor for

. Keep this booklet with the compressor for

future reference by the operatorfuture reference by the operator

future reference by the operator. P. P

. P. P

. Persons who have not read thisersons who have not read this

ersons who have not read thisersons who have not read this

ersons who have not read this

booklet should not use the air compressorbooklet should not use the air compressor

booklet should not use the air compressor..

..

.

WARNING!WARNING!

WARNING!

Compressed air can be dangerous. Death or serious injury couldCompressed air can be dangerous. Death or serious injury could

Compressed air can be dangerous. Death or serious injury could

result from improper or unsafe use of this compressorresult from improper or unsafe use of this compressor

result from improper or unsafe use of this compressor. T. T

. T. T

. To avoid theseo avoid these

o avoid theseo avoid these

o avoid these

risks, use your common sense and follow these basic safetyrisks, use your common sense and follow these basic safety

risks, use your common sense and follow these basic safety

instructions. Compressed air should never be inhaled as it mayinstructions. Compressed air should never be inhaled as it may

instructions. Compressed air should never be inhaled as it may

contain toxic vapours or solid particles. Always work in goodcontain toxic vapours or solid particles. Always work in good

contain toxic vapours or solid particles. Always work in good

ventilation, especially when spraying paints or other toxic substancesventilation, especially when spraying paints or other toxic substances

ventilation, especially when spraying paints or other toxic substances

and always use a suitable face mask. Do not spray near sources ofand always use a suitable face mask. Do not spray near sources of

and always use a suitable face mask. Do not spray near sources of

possible ignition.possible ignition.

possible ignition.

WARNING!WARNING!

WARNING!

Attachments, hoses and accessories must meet or exceed theAttachments, hoses and accessories must meet or exceed the

Attachments, hoses and accessories must meet or exceed the

maximum pressure rating of this compressormaximum pressure rating of this compressor

maximum pressure rating of this compressor..

..

.

If low pressure parts are used, the air pressure could cause them toIf low pressure parts are used, the air pressure could cause them to

If low pressure parts are used, the air pressure could cause them to

explode or fly aparexplode or fly apar

explode or fly apart, resulting in serious injurt, resulting in serious injur

t, resulting in serious injurt, resulting in serious injur

t, resulting in serious injuryy

yy

y. Always tak. Always tak

. Always tak. Always tak

. Always take greate great

e greate great

e great

care when releasing the pressure and connecting/disconnectingcare when releasing the pressure and connecting/disconnecting

care when releasing the pressure and connecting/disconnecting

tools.tools.

tools.

WARNING!WARNING!

WARNING!

This compressor must be connected to a power socket that isThis compressor must be connected to a power socket that is

This compressor must be connected to a power socket that is

safeguarded by a suitable circuit breaker or fuse.safeguarded by a suitable circuit breaker or fuse.

safeguarded by a suitable circuit breaker or fuse.

5

TRAINING:TRAINING:

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.

ALAL

ALWAWA

WAWA

WAYS USE EYE PROYS USE EYE PRO

YS USE EYE PROYS USE EYE PRO

YS USE EYE PROTECTIONTECTION

TECTIONTECTION

TECTION::

::

: 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 TNEVER T

NEVER TOUCH MOVING POUCH MOVING P

OUCH MOVING POUCH MOVING P

OUCH MOVING PARTSARTS

ARTSARTS

ARTS::

::

: Never place your hand near any moving parts

on the air compressor or operate with the covers removed.

PROTECT YOUR SELF AGAINST ELECTRIC SHOCK:PROTECT YOUR SELF AGAINST ELECTRIC SHOCK:

PROTECT YOUR SELF AGAINST ELECTRIC SHOCK: Never operate the air

compressor in wet or damp locations.

DRESS PROPERLDRESS PROPERL

DRESS PROPERLYY

YY

Y::

::

: Loose clothing or jewellery may be caught in moving parts.

Always tie long hair back.

KEEP VISITKEEP VISIT

KEEP VISITORS/CHILDREN AWAORS/CHILDREN AWA

ORS/CHILDREN AWAORS/CHILDREN AWA

ORS/CHILDREN AWAYY

YY

Y::

::

: 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 CLEANKEEP THE WORK AREA CLEAN

KEEP THE WORK AREA CLEAN::

::

: Cluttered areas invite accidents, clear the work

area of all unnecessary tools, debris and furniture.

DISCONNECT THE AIR COMPRESSORDISCONNECT THE AIR COMPRESSOR

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 NODO NO

DO NOT ABUSE THE CABLET ABUSE THE CABLE

T ABUSE THE CABLET ABUSE THE CABLE

T ABUSE THE CABLE::

::

: Never pull on the cable when removing the plug

from the socket, or lift the compressor by the mains cable.

BREATHING QUALITY AIR:BREATHING QUALITY AIR:

BREATHING QUALITY AIR: This compressor should not be used to supply breathing

quality air.

DO NODO NO

DO NOT ABUSE THE COMPRESSORT ABUSE THE COMPRESSOR

T ABUSE THE COMPRESSORT ABUSE THE COMPRESSOR

T ABUSE THE COMPRESSOR::

::

: Do not stand on the compressor.

SAFETY VSAFETY V

SAFETY VALAL

ALAL

ALVEVE

VEVE

VE::

::

: Never remove or attempt to adjust the safety valve. Keep the

safety valve free from paint and other accumulations.

AVOID UNINTENTIONAL STAVOID UNINTENTIONAL ST

AVOID UNINTENTIONAL STARTINGARTING

ARTINGARTING

ARTING::

::

: 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 OFFOFF

OFFOFF

OFF

(down) position.

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

6

STST

STORE THE AIR COMPRESSOR PROPERLORE THE AIR COMPRESSOR PROPERL

ORE THE AIR COMPRESSOR PROPERLORE THE AIR COMPRESSOR PROPERL

ORE THE AIR COMPRESSOR PROPERLYY

YY

Y::

::

: 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:PROTECT YOUR HEARING:

PROTECT YOUR HEARING: Ear protection should be worn when operating this

compressor.

MAINTAIN THE AIR COMPRESSOR WITH CARE:MAINTAIN THE AIR COMPRESSOR WITH CARE:

MAINTAIN THE AIR COMPRESSOR WITH CARE: If the air compressor is damaged in

any way, have it repaired by a qualified service engineer.

ONLONL

ONLY USE PY USE P

Y USE PY USE P

Y USE PARTS AND ACCESSORIES RECOMMENDED IN THIS MANUALARTS AND ACCESSORIES RECOMMENDED IN THIS MANUAL

ARTS AND ACCESSORIES RECOMMENDED IN THIS MANUALARTS AND ACCESSORIES RECOMMENDED IN THIS MANUAL

ARTS 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.

STST

STAA

AA

AY ALERTY ALERT

Y ALERTY ALERT

Y 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 DAMAGEDBEFORE EACH USE CHECK THE AIR COMPRESSOR AND HOSE FOR DAMAGED

BEFORE EACH USE CHECK THE AIR COMPRESSOR AND HOSE FOR DAMAGED

PP

PARTSARTS

ARTSARTS

ARTS::

::

: 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 CAREFULLHANDLE THE AIR COMPRESSOR CAREFULL

HANDLE THE AIR COMPRESSOR CAREFULLYY

YY

Y::

::

: 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 MOKEEP THE MO

KEEP THE MOTT

TT

TOR AIR VENT CLEAROR AIR VENT CLEAR

OR AIR VENT CLEAROR AIR VENT CLEAR

OR 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.

OPERAOPERA

OPERATE THE AIR COMPRESSOR ATE THE AIR COMPRESSOR A

TE THE AIR COMPRESSOR ATE THE AIR COMPRESSOR A

TE THE AIR COMPRESSOR AT THE CORRECT VOLT THE CORRECT VOL

T THE CORRECT VOLT THE CORRECT VOL

T THE CORRECT VOLTT

TT

TAGEAGE

AGEAGE

AGE::

::

: Make sure that the

mains supply voltage is the same as the voltage shown on the rating plate.

DO NODO NO

DO NOT WIPE THE PLAT WIPE THE PLA

T WIPE THE PLAT WIPE THE PLA

T WIPE THE PLASTIC PSTIC P

STIC PSTIC P

STIC PARTS WITH SOLARTS WITH SOL

ARTS WITH SOLARTS WITH SOL

ARTS WITH SOLVENTVENT

VENTVENT

VENT::

::

: 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 TIGHTLKEEP ALL SCREWS AND COVERS TIGHTL

KEEP ALL SCREWS AND COVERS TIGHTLY IN PLACEY IN PLACE

Y IN PLACEY IN PLACE

Y IN PLACE::

::

: Check the screws and covers

periodically.

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

7

ADEQUATE VENTILATION:ADEQUATE VENTILATION:

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 ISNEVER USE AN AIR COMPRESSOR WHICH APPEARS DEFECTIVE OR IS

NEVER USE AN AIR COMPRESSOR WHICH APPEARS DEFECTIVE OR IS

OPERAOPERA

OPERATING ABNORMALLTING ABNORMALL

TING ABNORMALLTING ABNORMALL

TING ABNORMALLYY

YY

Y::

::

: 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 MODIFY THE AIR COMPRESSOR:

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 NODO NO

DO NOT MODIFY THE TT MODIFY THE T

T MODIFY THE TT MODIFY THE T

T MODIFY THE TANKANK

ANKANK

ANK::

::

: Do not modify the tank or operate at pressures or

temperatures outside the limits stated in this booklet.

TURN OFF THE AIR COMPRESSOR WHEN NOTURN OFF THE AIR COMPRESSOR WHEN NO

TURN OFF THE AIR COMPRESSOR WHEN NOT IN USET IN USE

T IN USET IN USE

T 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 NODO NO

DO NOT TT T

T TT T

T TOUCH HOOUCH HO

OUCH HOOUCH HO

OUCH HOT SURFT SURF

T SURFT SURF

T SURFACESACES

ACESACES

ACES::

::

: During operation, the motor, connections,

compressor body, cylinder head and tubes may get hot, please take care.

DO NODO NO

DO NOT DIRECT THE AIR STREAM AT DIRECT THE AIR STREAM A

T DIRECT THE AIR STREAM AT DIRECT THE AIR STREAM A

T DIRECT THE AIR STREAM AT THE BODYT THE BODY

T THE BODYT THE BODY

T 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.

ONLONL

ONLY USE RECOMMENDED PY USE RECOMMENDED P

Y USE RECOMMENDED PY USE RECOMMENDED P

Y USE RECOMMENDED PARTSARTS

ARTSARTS

ARTS::

::

: To avoid the risk of bursting, only hoses with a

rated pressure of 10 bar, or more should be used. Never attempt to repair faulty

hoses.

DO NODO NO

DO NOT USE THIS COMPRESSOR TT USE THIS COMPRESSOR T

T USE THIS COMPRESSOR TT USE THIS COMPRESSOR T

T USE THIS COMPRESSOR TO INFLAO INFLA

O INFLAO INFLA

O INFLATE SMALLTE SMALL

TE SMALLTE SMALL

TE SMALL, L, L

, L, L

, LOWOW

OWOW

OW-PRESSURE OBJECTS-PRESSURE OBJECTS

-PRESSURE OBJECTS-PRESSURE OBJECTS

-PRESSURE OBJECTS::

::

: Items

such as children's toys or footballs can explode if over-inflated.

AVOID KINKING OR TRAPPING THE AIR HOSEAVOID KINKING OR TRAPPING THE AIR HOSE

AVOID KINKING OR TRAPPING THE AIR HOSE::

::

: Always replace faulty hoses - never

attempt a repair if a leak is detected.

DRAIN TDRAIN T

DRAIN TANKANK

ANKANK

ANK::

::

: 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 OFFNEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF

NEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF

AA

AT THE MAINS SUPPLT THE MAINS SUPPL

T THE MAINS SUPPLT THE MAINS SUPPL

T THE MAINS SUPPLYY

YY

Y::

::

: Always use the On/Off switch on the compressor.

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

8

NEVER OPERATE WITHOUT ALL GUARDS IN PLACE:NEVER OPERATE WITHOUT ALL GUARDS IN PLACE:

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:NEVER OPERATE IN THE PRESENCE OF FLAMMABLE LIQUIDS OR GASES:

NEVER OPERATE IN THE PRESENCE OF FLAMMABLE LIQUIDS OR GASES: The air

compressor produces sparks during operation.

CHECK FOR DAMAGED PCHECK FOR DAMAGED P

CHECK FOR DAMAGED PARTS AND AIR LEAKSARTS AND AIR LEAKS

ARTS AND AIR LEAKSARTS AND AIR LEAKS

ARTS 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.

ONLONL

ONLY USE WITHIN THE RECOMMENDED OPERAY USE WITHIN THE RECOMMENDED OPERA

Y USE WITHIN THE RECOMMENDED OPERAY USE WITHIN THE RECOMMENDED OPERA

Y USE WITHIN THE RECOMMENDED OPERATING TEMPERATING TEMPERA

TING TEMPERATING TEMPERA

TING TEMPERATURE RANGETURE RANGE

TURE RANGETURE RANGE

TURE RANGE::

::

: This

compressor should only be used in an ambient temperature of between 0OC

and 25OC.

CLEANING AND CONDITION OF THE COMPRESSORCLEANING AND CONDITION OF THE COMPRESSOR

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 COMPRESSORMOVING THE COMPRESSOR

MOVING THE COMPRESSOR::

::

: Always transport the compressor by lifting or pulling

it with the appropriate grips or handles.

USING THE COMPRESSOR FOR PUSING THE COMPRESSOR FOR P

USING THE COMPRESSOR FOR PAINTINGAINTING

AINTINGAINTING

AINTING::

::

:

• 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:MOTOR HOUSING:

MOTOR HOUSING: Do not insert your fingers or other objects inside the motor

housing to avoid physical damage or damage to the compressor.

SAFETY PRECAUTIONSSAFETY PRECAUTIONS

SAFETY PRECAUTIONS

9

WARNING SYMBOLSWARNING SYMBOLS

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.

10

ELECTRICAL CONNECTIONSELECTRICAL CONNECTIONS

ELECTRICAL CONNECTIONS

Connect the mains lead to a 230 Volt (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.DO NOT connect to a domestic system via a 13 AMP plug.

DO NOT connect to a domestic system via a 13 AMP plug.

WARNING! THIS APPLIANCE MUST BE EARTHEDWARNING! THIS APPLIANCE MUST BE EARTHED

WARNING! THIS APPLIANCE MUST BE EARTHED

IMPORTIMPORT

IMPORTANTANT

ANTANT

ANT::

::

: 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 aWe recommend that this machine is connected to the mains supply via a

We recommend that this machine is connected to the mains supply via a

Residual Current Device (RCD)Residual Current Device (RCD)

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 [email protected]020 8988 7400 or e-mail [email protected]

020 8988 7400 or e-mail [email protected]

11

PARTS IDENTIFICAPARTS IDENTIFICA

PARTS IDENTIFICATIONTION

TIONTION

TION

11

1

88

8

99

9

1010

10

1111

11

1212

12

1313

13

77

7

1 Motor housing

2 On/Off switch (red button)

3 Main reservoir pressure gauge

4 Output pressure regulator

5 Regulator locking ring

6 Output pressure gauge

7 Trolley handle

8 Support foot

9 Drain valve

10 Compressed air reservoir

11 Transportation wheel

12 Data plate

13 Pressure regulator and cut-out

14 Oil dipstick

15 Outlet tap

1414

14

22

2

44

4

33

3

66

6

55

5

1515

15

12

AA

ASSEMBLSSEMBL

SSEMBLSSEMBL

SSEMBLYY

YY

Y

WW

WARNING!ARNING!

ARNING!ARNING!

ARNING!

BeforBefor

Before assembling and using the air compre assembling and using the air compr

e assembling and using the air compre assembling and using the air compr

e assembling and using the air compressoressor

essoressor

essor, mak, mak

, mak, mak

, make sure sur

e sure sur

e sure that you havee that you have

e that you havee that you have

e that you have

rr

read and understood all of the safety instructions.ead and understood all of the safety instructions.

ead and understood all of the safety instructions.ead and understood all of the safety instructions.

ead and understood all of the safety instructions.

InstallationInstallation

Installation

Take care when lifting the compressor from the packaging.

CAUTION! Do not lift the compressor from the gauge of fittings assemblyCAUTION! Do not lift the compressor from the gauge of fittings assembly

CAUTION! Do not lift the compressor from the gauge of fittings assembly. Get. Get

. Get. Get

. Get

assistance if necessary. This unit weighs 57kg.assistance if necessary. This unit weighs 57kg.

assistance if necessary. This unit weighs 57kg.

After removing the compressor from its packaging, check the integrity of the

unit, making sure it has not been damaged in transit.

Fitting the wheelsFitting the wheels

Fitting the wheels

Slide a wheel on to each axle and secure using the push on fasteners provided.

Use a suitable piece of tube or an old socket to tap the fasteners in place.

Push on

fastener

Figure 1 Figure 2

LL

Locating the air compressorocating the air compressor

ocating the air compressorocating the air compressor

ocating the air compressor

This compressor should be positioned on a

stable, flat surface (or one with a maximum

inclination of 15O), See figure 3, and ensure it is

completely stable

If it is placed on a shelf or surface raised off

the ground, it must be secured appropriately

to prevent it from tipping off during use.

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 3

1234567890123456789012

1

23456789012345678901

2

1234567890123456789012

150

max

13

AA

ASSEMBLSSEMBL

SSEMBLSSEMBL

SSEMBLYY

YY

Y

Moving the air compressorMoving the air compressor

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, take care when lifting and moving this compressor to

avoid personal injury. Get assistance if necessary.

PREPPREP

PREPARING FOR USEARING FOR USE

ARING FOR USEARING FOR USE

ARING FOR USE

Before connecting your compressor to the mains supply,

Check the OilCheck the Oil

Check the Oil

1 Check the sight glass, and ensure the oil level

is between the min and max mark. See figure

4.

• If needed top up the reservoir with Clarke

SAE 40 Compressor oil, available from your

Clarke dealer.

Figure 4

14

PREPPREP

PREPARING FOR USEARING FOR USE

ARING FOR USEARING FOR USE

ARING 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.

IMPORIMPOR

IMPORTT

TT

TANTANT

ANTANT

ANT: If the r: If the r

: If the r: If the r

: If the receiver is under preceiver is under pr

eceiver is under preceiver is under pr

eceiver is under pressuressur

essuressur

essure, ke, k

e, ke, k

e, keep your hands well awayeep your hands well away

eep your hands well awayeep your hands well away

eep your hands well away

frfr

from the air being expelled.... rom the air being expelled.... r

om the air being expelled.... rom the air being expelled.... r

om the air being expelled.... rememberemember

ememberemember

emember, compr, compr

, compr, compr

, compressed air is Dessed air is D

essed air is Dessed air is D

essed air is DANGEROUS!ANGEROUS!

ANGEROUS!ANGEROUS!

ANGEROUS!

WW

WARNING!ARNING!

ARNING!ARNING!

ARNING!

BeforBefor

Before connecting any air tool, make connecting any air tool, mak

e connecting any air tool, make connecting any air tool, mak

e connecting any air tool, make sure sur

e sure sur

e sure you have re you have r

e you have re you have r

e you have read and fullyead and fully

ead and fullyead and fully

ead and fully

understood the manufacturunderstood the manufactur

understood the manufacturers instruction booklet for the tool being used.ers instruction booklet for the tool being used.

ers instruction booklet for the tool being used.ers instruction booklet for the tool being used.

ers instruction booklet for the tool being used.

Also ensurAlso ensur

Also ensure that the tool is compatible with the compre that the tool is compatible with the compr

e that the tool is compatible with the compre that the tool is compatible with the compr

e that the tool is compatible with the compressor and hoseessor and hose

essor and hoseessor and hose

essor and hose

specifications.specifications.

specifications.

If the prIf the pr

If the pressuressur

essuressur

essure rating of the tool is less than 10 bare rating of the tool is less than 10 bar

e rating of the tool is less than 10 bare rating of the tool is less than 10 bar

e rating of the tool is less than 10 bar, the pr, the pr

, the pr, the pr

, the pressuressur

essuressur

essure re r

e re r

e regulator mustegulator must

egulator mustegulator must

egulator must

be used to adjust the output prbe used to adjust the output pr

be used to adjust the output pressuressur

essuressur

essure.e.

e.e.

e.

1 Ensure that the red On/Off switch is set to

the OFF position (pressed down). See

figure 5.

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 the outlet tap

using the hose nut. See figure 6. Hose nut

Figure 6

Figure 5

On/Off Switch

15

OPERAOPERA

OPERATING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONS

Switching the air compressor ONSwitching the air compressor ON

Switching the air compressor ON

The compressor will makThe compressor will mak

The compressor will make a continuous loud noise when the tank is charging -e a continuous loud noise when the tank is charging -

e a continuous loud noise when the tank is charging -e a continuous loud noise when the tank is charging -

e a continuous loud noise when the tank is charging -

this is normalthis is normal

this is normal..

..

.

1 Lift the red On/Off switch located on top of the pressure regulator to switch

the compressor ON.

• The compressor will then charge the main tank to 10 bar (145 psi). When

this pressure is reached, the compressor will 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 7. 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.

WW

WARNING!ARNING!

ARNING!ARNING!

ARNING!

Do not rDo not r

Do not remove or attempt to adjust the safety valve.emove or attempt to adjust the safety valve.

emove or attempt to adjust the safety valve.emove or attempt to adjust the safety valve.

emove or attempt to adjust the safety valve.

3 Loosen the locking ring and select the

pressure you need using the pressure

regulator.

4 Tighten the locking ring by holding the

pressure regulator firmly in place and

rotating the locking ring anticlockwise

until it tightens against the underside

of the pressure regulator. See figure 8.

• This will prevent you from

accidentally increasing the

pressure to a dangerous level.

Figure 8

Figure 7

Pressure

regulator

Locking ring

Output pressure

gauge

16

5 The illustration below shows the pressure regulator locked at 6 bar .

• Never set the pressure higher than the rated pressure of the attachments

being used, as there is a risk of bursting and resultant injury.

To increase the output pressure from this value you will need to loosen the

locking ring.

• Only alter this setting if you are using an air tool which is capable of

supporting the higher pressure.

6 Open the outlet tap.

OPERAOPERA

OPERATING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONS

PP

Pressure regulatorressure regulator

ressure regulatorressure regulator

ressure regulator

Regulator locking ringRegulator locking ring

Regulator locking ring

locklock

locked at desireded at desired

ed at desireded at desired

ed at desired

pressurepressure

pressure..

..

.

Output pressure gaugeOutput pressure gauge

Output pressure gauge

MainMain

Main

reserreser

reservoirvoir

voirvoir

voir

pressurepressure

pressure

gaugegauge

gauge

Figure 9

OutletOutlet

Outlet

taptap

tap

17

OPERAOPERA

OPERATING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONS

Switching the air compressor OFFSwitching the air compressor OFF

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 air compressor.

2. Switch off the mains supply and remove the plug.

• You should never leave the compressor air reservoir unattended while

under pressure.

• Always release the pressure from the reservoir when not in use or prior

to storage, as described in 'Draining the reservoir' on page 18.

RR

Removing a tool from the air hoseemoving a tool from the air hose

emoving a tool from the air hoseemoving a tool from the air hose

emoving a tool from the air hose

WW

WARNING!ARNING!

ARNING!ARNING!

ARNING!

Always set the prAlways set the pr

Always set the pressuressur

essuressur

essure re r

e re r

e regulator to zeregulator to zer

egulator to zeregulator to zer

egulator to zero beforo befor

o beforo befor

o before attempting to re attempting to r

e attempting to re attempting to r

e attempting to remove oremove or

emove oremove or

emove or

rr

replace a tool.eplace a tool.

eplace a tool.eplace a tool.

eplace a tool.

1 Stop the power supply by pressing down on the on/off button (red button)

located on top of the air compressor.

22

2Close the air outlet tap and trigger the equipment (spraygun, air tool etc),Close the air outlet tap and trigger the equipment (spraygun, air tool etc),

Close the air outlet tap and trigger the equipment (spraygun, air tool etc),Close the air outlet tap and trigger the equipment (spraygun, air tool etc),

Close the air outlet tap and trigger the equipment (spraygun, air tool etc),

to release air from the air hoseto release air from the air hose

to release air from the air hose BEFOREBEFORE

BEFOREBEFORE

BEFORE disconnecting the hose from thedisconnecting the hose from the

disconnecting the hose from thedisconnecting the hose from the

disconnecting the hose from the

machine.machine.

machine.

Reset buttonReset button

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 10.

If you restart the compressor and the

overload cutout activates again, switch off

the compressor, remove the plug from the

mains and have your compressor checked by a qualified service agent.

Figure 10

18

Draining the reserDraining the reser

Draining the reservoirvoir

voirvoir

voir

CAUTION! It is important to drain the reserCAUTION! It is important to drain the reser

CAUTION! It is important to drain the reservoir before storagevoir before storage

voir before storagevoir before storage

voir before storage..

..

.

1 Press 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

condensate.

2 Carefully undo the drain valve anticlockwise until you hear a hissing noise,

this is the reservoir depressurising. See figure 11.

• When the reservoir pressure gauge indicates zero and the hissing has

stopped, tighten the drain valve again.

OPERAOPERA

OPERATING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONSTING INSTRUCTIONS

TING INSTRUCTIONS

Figure 11

Drain valve

19

Figure 12

ROUTINE MAINTENANCEROUTINE MAINTENANCE

ROUTINE MAINTENANCE

IMPORIMPOR

IMPORTT

TT

TANTANT

ANTANT

ANT: Befor: Befor

: Befor: Befor

: Before carre carr

e carre carr

e carrying out any maintenance, always disconnect theying out any maintenance, always disconnect the

ying out any maintenance, always disconnect theying out any maintenance, always disconnect the

ying out any maintenance, always disconnect the

comprcompr

compressor fressor fr

essor fressor fr

essor from the mains supplyom the mains supply

om the mains supplyom the mains supply

om the mains supply, drain the air r, drain the air r

, drain the air r, drain the air r

, drain the air receiver and, if necessareceiver and, if necessar

eceiver and, if necessareceiver and, if necessar

eceiver and, if necessaryy

yy

y,,

,,

,

allow the machine to cool down beforallow the machine to cool down befor

allow the machine to cool down before stare star

e stare star

e starting work.ting work.

ting work.ting work.

ting work.

DailyDaily

Daily

Check OilCheck Oil

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 40compressor oil, available from

your local dealer).

Drain the tankDrain the tank

Drain the tank

After use, always open the drain valve to ensure that any liquid that may have

condensed, is drained off. See page 18.

MonthlyMonthly

Monthly

The air intake filter should be inspected on a MONTHLMONTHL

MONTHLMONTHL

MONTHLYY

YY

Y basis, and more often in

dusty conditions,

TT

To clean the air intako clean the air intak

o clean the air intako clean the air intak

o clean the air intake filtere filter

e filtere filter

e filter,,

,,

,

1 Pull the filter cover away from the

compressor as shown. See figure 12.

2 Remove the sponge filter from the

filter cover. See figure 13.

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 13

20

ROUTINE MAINTENANCEROUTINE MAINTENANCE

ROUTINE MAINTENANCE

Every six monthsEvery six months

Every six months

Make sure that all bolts are securely tightened.

Clean all the external parts of the

compressor.

OilOil

Oil

After the first 100 hours use, replace the

oil completely using Clarke SAE40

compressor oil. Thereafter, replace the oil

completely 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 RNon R

Non Return Veturn V

eturn Veturn V

eturn Valvealve

alvealve

alve

Examine the non-return valve, and

replace the gasket and valve if

necessary

Figure 4

Figure 15

Figure 16

Clarke BOXER 55 Installation and operation manual

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