Clarke BOXER II 18/200 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
GC0721
ORIGINAL INSTRUCTIONS
200L BELT DRIVEN AIR COMPRESSOR
MODEL NO: BOXER II 18/200
PART NO: 2245317

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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.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

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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 precautions.
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 any 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 when using this compressor.
Wear ear protectors when using this compressor.
This compressor produces a high sound level during
operation.

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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.
• The BROWN wire must
be 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.
CHECKING THE OIL LEVEL
1. Ensure the oil level is filled up to
the mark on the sightglass.
2. If low, top up after unscrewing the
filler plug.
• Only use ISO100 (SAE30)
compressor oil, available from
your CLARKE dealer Part No.
3050796.
• Take care not to overfill.

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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.
•DO NOT lift by (or put strain on) valves or hoses.
• Avoid moving the compressor when fully pressurised.
ATTACHING AIR TOOLS
1. Attach the air hose to the outlet
valves.
2. Attach the air tool to the other
end of the air hose.
3. Turn the outlet valve handle to the
open position.
NOTE: The outlet valve is shown
without the air hose fitted for
clarity.
NOTE: To adjust the output pressure
we recommend that a
pressure regulator (not
supplied) be fitted between
the compressor and the tool.
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.
CHECKING THE SAFETY VALVE
To make sure that the safety valve works correctly.
1. Unscrew and pull the knurled part
of the safety valve.
• Air will be released when you
pull hard on the valve end and
stop when released.
2. If the valve does not operate in
this way, do not use the
compressor. The compressor must
be repaired by a qualified service
agent.
3. Once tested, screw the knurled part back in.
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
closed 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.

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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.
USING THE 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
After use, open the drain valve to make sure that any condensate is drained
off.
CHECK OIL
Ensure the oil level is between the min and max marks on the dipstick. See
“Checking the Oil level” on page 6 and top-up if necessary - (use CLARKE
ISO100 (SAE30) compressor oil, available from your local CLARKE dealer).
CLEAN THE AIR FILTER
The air filter should be inspected monthly or more often in dusty conditions.
1. Remove the fixing bolts with a
7/32” hex key and pull the filter
from the engine.
2. Remove the filter element and
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 element is damaged it must be replaced.
3. Reassemble the filter and refit it to the compressor.
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.
CHECKING THE NON-RETURN VALVE
If the reservoir pressure decreases for no apparent reason, it is possible that the
non-return valve is leaking. To check this:
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.
WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM
THE ELECTRICAL SUPPLY BEFORE REPLACING THE DRIVE BELT.
WARNING: NEVER USE THE COMPRESSOR WITH THE GUARD REMOVED.

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SPECIFICATIONS
Part Number 2245317
Motor size 4HP
Voltage 230 VAC (50Hz)
Air Displacement 504.8L/min (18 CFM)
Max Pressure 10 Bar (145psi)
Receiver Capacity 200 L
Ingress Protection IP20
Fuse Rating 13 A
Duty cycle S3/50%
Oil requirements Compressor oil SAE30
Oil capacity 0.4L
Dimensions (L x W x H) 1540 x 400 x 820 mm
Guaranteed Sound Power Level 97 dB(A)
Weight 102 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.
MODEL BOXER 18/200

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TROUBLESHOOTING
CAUTION: DO NOT TRY TO REPAIR OR ADJUST 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 CLARKE dealer
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.
Compressor is
very noisy and
makes metallic
knocking
sound.
Compressor is damaged
and needs overhaul.
1. Return the machine to your
nearest CLARKE dealer

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COMPONENT PARTS

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COMPONENT PARTS LIST
NO DESCRIPTION
1Crankcase
2Cylinder block
3Cylinder Head
4Crankshaft
5Lower Cover
6Kit Valve Holder
7Conrod
8Air Filter Assembly (complete)
9Air cooler
10 End Cover
11 Bearing Retainer
12 Flywheel
13 Bearing
14 Oil Filler
15 Oil seal
16 O-ring
17 Bolt
18 Washer
19 Piston Ring Set
20 Piston
21 Gudgeon pin
22 Circlip
23 Piston Kit
24 Intake Air Filter
25 Gasket Set
26 Cold Start Valve
27 Non Return Valve
28 Rilsan Tube
29 Plastic Shroud
30 Delivery pipe
31 Pressure Switch
32 Power Cable
33 Motor
34 Belt Guard
35 Safety valve
36 Pump assembly
37 Feet set
38 Drive pulley
39 Drive Belt
40 Outlet Tap
41 Drain Valve
42 Upright Connector
43 Connector
44 Pressure Gauge
45 Oil Seal
46 Drain plug
47 Sightglass
NO DESCRIPTION

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY