Clarke BOXER 55 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS ©
BOXER 55
AIR COMPRESSOR
1010
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.
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 product, ensure it is disposed of according to all local ordinances. It must
not be disposed of with general household waste.

3
CONTENTS 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 PRECAUTIONS
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.

5
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 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.
SAFETY PRECAUTIONS

6
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.
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.
SAFETY PRECAUTIONS

7
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.
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 10 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.
SAFETY PRECAUTIONS

8
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

9
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 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 [email protected]

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PARTS IDENTIFICATION
1
7
8
9
10
11
12
6
1 Motor housing
2 On/Off switch (red button)
3 Main reservoir pressure gauge
4 Output pressure regulator
5 Output pressure gauge
6 Trolley 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 dipstick
14 Outlet tap
13
2
4
3
5
14
14

12
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 from the gauge of fittings assembly. Get
assistance if necessary. This unit weighs 54.5 kg.
After removing the compressor from its packaging, check the integrity of the
unit, making sure it has not been damaged in transit.
Fitting the Wheels / Feet
1. Fix a wheel to each side of the compressor and secure using the stub axle and
nut supplied. see Figure 1. Cover the stub axle using the cap provided.
2. Fix the two front feet as shown in figure 2.
Figure 1 Figure 2
Fitting the Handle
1. Place the handle in the correct
position and secure using the 4 bolts
supplied.
Figure 3

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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.
PREPARING FOR USE
Before connecting your compressor to the mains supply,
Check the Oil
1 Check the sight glass, and ensure the oil level
is between the min and max mark. See figure
5.
• If needed top up the reservoir with Clarke
SAE 40 Compressor oil, available from your
Clarke dealer.
Figure 5
Figure 4
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1
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2
1
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2
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150
max
Locating the air compressor
This compressor should be positioned on a
stable, flat surface (or one with a maximum
inclination of 15O), See figure 4, 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.

14
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 receiver 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.
If the pressure rating of the tool is less than 10 bar, 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 6.
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
connector.
On/Off Switch
Figure 6

15
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 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.
WARNING!
Do not remove or attempt to adjust the safety valve.
3 Release the pressure regulater by
pulling it out, turn it to select the
pressure you need.
4 Lock the pressure regulator by pushing
it it towards the guages. See figure 8.
• This will prevent you from
accidentally increasing the pressure
to a dangerous level.
Figure 8
Figure 7
Pressure
regulator
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 release the
locking ring by pulling it outwards.
• Only alter this setting if you are using an air tool which is capable of
supporting the higher pressure.
OPERATING INSTRUCTIONS
Pressure regulator
Output pressure gauge
Main
reservoir
pressure
gauge
Figure 9
Outlet
Outlet

17
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 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.
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 air compressor.
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 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 reservoir
CAUTION! It is important to drain the reservoir 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.
OPERATING INSTRUCTIONS
Figure 11
Drain valve

19
Figure 12
ROUTINE MAINTENANCE
IMPORTANT: Before carrying out any maintenance, 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 40compressor 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 18.
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 Remove the screw and 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 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 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 Return Valve
Examine the non-return valve, and
replace the gasket and valve if
necessary
Figure 14
Figure 15
Figure 16