Clarke CFP11F Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1020
AIR COMPRESSOR
MODEL NO: CFP11F
PART NO: 2090908

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INTRODUCTION
Thank you for purchasing this CLARKE Engine Driven Compressor.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
IMPORTANT
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.
WARNING: THIS SYMBOL IS USED THROUGHOUT THE USER GUIDE WHEN
THERE IS A RISK OF PERSONNAL INJURY. MAKE SURE THAT THESE
WARNINGS ARE READ AND UNDERSTOOD AT ALL TIMES.
CAUTION: THIS SYMBOL IS USED THROUGHOUT THE USER GUIDE WHEN
THERE IS A RISK OF DAMAGE TO THE PRODUCT. MAKE SURE THAT THESE
CAUTIONS ARE READ AND UNDERSTOOD AT ALL TIMES.

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GENERAL SAFETY PRECAUTIONS
Before using your compressor, read and pay attention to the following safety
guidelines.
1. Make sure that all persons using the compressor have read and fully
understand these operating instructions and had any necessary training
2. Compressed air is dangerous. DO NOT point a jet of air at persons or
animals or discharge compressed air against the skin.
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 receiver.
5. DO NOT leave pressure in the air receiver overnight or when transporting.
6. DO NOT adjust or tamper with the safety valve. The maximum pressure is
set at the factory.
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 metal parts can become hot during operation. DO NOT touch these
until the compressor has cooled down.
9. ALWAYS set the pressure regulator to the recommended setting for the air
tool being used.
10. When spraying flammable materials e.g. cellulose paint, ensure that there
is sufficient ventilation and keep clear of any source of ignition.
11. DO NOT use this compressor in explosive atmospheres.
12. DO NOT operate this compressor in a confined space unless additional
ventilation is provided.
13. Before spraying any material always consult paint manufacturers
instructions for safety and usage.
14. Wear PPE such as goggles to protect your eyes from flying particles. Face
masks will protect you against paint spray and fumes.
15. This compressor will produce noise levels in excess of 70dB(A). Persons
working near the compressor must be equipped with ear protection.
16. Make sure that air hoses are not kinked or wrapped around the compressor
and not subjected to strain.

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17. When disconnecting air hoses from your compressor, make sure that the air
supply is turned off at the outlet and vent all pressurised air from within the
air receiver.
18. Make sure that children and animals are kept well away from the
compressor and any airline equipment attached to it.
19. Make sure that any equipment or air tool used in conjunction with your
compressor has a safe working pressure exceeding that of the compressor.
20. Take care when transporting the compressor to prevent tipping over with
resultant spillage of fluids.
SAFETY SYMBOLS
The following safety symbols are found on the product.
Refer to instruction
manual/booklet.
Warning or Caution
Hot surface-Do not
touch
Hazard of flammable
materials
Wear eye protection Toxic fumes may be
emitted
Wear ear protection This compressor
produces high noise
level during operation.

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BEFORE USE
POSITIONING THE AIR COMPRESSOR IN THE WORKPLACE
1. ALWAYS carry the compressor using the handle.
2. DO NOT lift by (or put strain on) valves or hoses.
3. Before starting, ensure the compressor is standing on a firm level surface
which does not exceed 10oincline, either transversely or longitudinally.
4. Ensure the environment is dry and dust free.
5. Ensure there is adequate ventilation for:
• Air intake to the compressor pump and engine.
• Cooling for the compressor pump and engine.
• Engine exhaust gases.
FILING WITH OIL
The engine and compressor are
supplied without oil inside.
A 1 litre bottle of dual purpose oil is
provided in the box and must be
added before use (approx 0.6 L to
the engine and 0.4 L to the
compressor).
For future use, suitable oils are
available from your CLARKE dealer:
1 litre of SAE30 Engine oil - Part No.
3050852
1 litre of SAE30 Air Compressor oil - Part No. 3050796
AIR COMPRESSOR (PUMP)
Remove the compressor dipstick and
add 0.4 L of compressor oil to the
compressor. Check the oil level on
the dipstick

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ENGINE
Remove the engine dipstick and add
0.6 L of engine oil to the engine.
Check that the oil level on the
dipstick is within the hatched area
when the dipstick is removed from
the engine.
Ensure the oil level is visible between
the high (H) and low (L) marks on the
engine dipstick.
ADDING FUEL
Remove the filler cap and fill the tank
with unleaded fuel. (Max capacity
1.8 L)
• Use a funnel to avoid
accidental spillage of fuel.
• If fuel is spilled it must be
cleaned from the unit and
surrounding area before
attempting to start the engine.
• Do not overfill.
CAUTION: DO NOT SMOKE
CAUTION: LET A HOT ENGINE COOL BEFORE REFULING
CAUTION: KEEP FUEL OUT OF REACH OF CHILDREN
CAUTION: ENSURE GOOD VENTILATION AWAY FROM SOURCES OF
IGNITION

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STARTING AND USING THE COMPRESSOR
STARTING THE ENGINE FOR THE FIRST TIME
NOTE: For first time operation, do not connect the air hose or any tools
and proceed as follows:
1. Turn fuel valve to the ON position.
2. Set the choke lever to the
(starting) position.
3. Set the engine switch to the “I”
(ON) position.
4. Hold the starting handle firmly and
pull lightly until you start to feel
resistance, then pull sharply to
start the engine.
NOTE: You may have to do this
more than once.
WARNING: ONCE THE ENGINE HAS STARTED, ALLOW THE STARTING
HANDLE TO RECOIL SLOWLY TO AVOID INJURY/DAMAGE AS IT WHIPS
BACK.

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5. When the engine is running steadily, gradually return the choke lever to the
normal running position (to the right).
6. When the engine is running steadily, turn off and attach an air hose to the
compressed air outlet and to the air driven tool.
OIL ALERT SYSTEM
An oil alert system is fitted to prevent engine damage caused by insufficient oil
in the crankcase. Before the oil can fall below a safe limit the oil alert system
will automatically stop the engine although the throttle lever remains in a
running position.
If the engine stops and will not re-start, check the engine oil level before
troubleshooting other areas.
ATTACHING AIR TOOLS
1. Attach the air hose to the air
outlet using an appropriate
connector.
2. Attach the air tool to the other
end of the air hose.
• If using snap couplings, use a
whip end, available from your
CLARKE dealer.
3. Restart the engine and allow
pressure to build up in the
receiver.
• The gauge will show the available pressure in the receiver.
4. Check the system for air leaks. If any are apparent, stop the engine and
operate the air tool until the air pressure is at zero before rectifying leaks.
NOTE: A self-relieving regulator is fitted which will vent excess air pressure
from the bleed hole when the pressure reaches the maximum.
operating pressure for the compressor.
5. Turn the pressure regulator (clockwise to increase pressure) and proceed
to use your air tool in accordance with its own product instructions.
WARNING: BEFORE CONNECTING AIR TOOLS, MAKE SURE THAT YOU
READ THE INSTRUCTIONS SUPPLIED WITH THE TOOL. ENSURE THAT THE AIR
TOOL IS SUITABLE FOR USE WITH THIS COMPRESSOR AND HOSE
SPECIFICATIONS.

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SUBSEQUENT STARTING
1. Connect the air hose to the air outlet and tool and set the pressure
regulator to zero pressure (turned fully anticlockwise).
2. Start the engine and allow pressure to build up.
3. When the pressure in the receiver has built up and air is expelled at the
vent hole, turn the outlet pressure regulator clockwise so that the desired
pressure is shown on the pressure gauge.
4. Check for air leaks at the air tool and connectors before proceeding.
STOPPING THE COMPRESSOR
1. At the end of the day, stop the engine by turning the engine switch to OFF
and closing the fuel valve.
2. Put a container below the drain valve to collect the condensate.
3. Open the drain valves slowly.
• Condensation will drain from
the air receiver.
4. Close the drain valve when the air
receiver has fully drained.
5. Turn the air regulator fully
anticlockwise to close off the air
supply.
6. Operate the air tool to discharge
any pressure in the air line before disconnecting the airline and the air tool.
CAUTION: TAKE CARE NOT TO TOUCH THE ENGINE OR COMPRESSOR AS
THEY REMAIN HOT FOR SOME TIME AFTER USE.
CAUTION: DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO REMOVE
THE AIR TOOL OR DISCONNECT THE AIR HOSE UNTIL YOU ARE SATISFIED
THAT THE PRESSURE HAS BEEN RELEASED.

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COMPRESSED AIR REQUIREMENTS
• If an unusually long air hose is required, (over 8 metres), the line
pressure or the hose inside diameter may need to be increased.
• The air hose must be rated at least 150% of the maximum operating
pressure of the tool.
• If an automatic in-line lubricator/ filter is used it will keep the air tool
in good condition but should be regularly checked & topped up
with oil. CLARKE air-line oil should be used and the lubricator
adjusted to approx 2 drops per minute.
• Never exceed the maximum operating pressure for the air tool.
Higher pressures and contaminated air will shorten the life of the tool
due to faster wear and is a possible safety hazard.
MAINTENANCE
DRAIN THE AIR RECEIVER (DAILY/BEFORE USE)
After use, always open the drain
valve(s) to make sure that any
condensate is drained off.
CHECK OIL (DAILY)
1. Check the engine oil level is
between the Low and High marks
on the dipstick and top-up if
necessary.
2. Check the compressor oil level in
the same way.
3. Remove each dipstick and wipe it clean. Insert the dipstick into the hole as
far as it will go, then remove it to check the oil level. Do not overfill. Refit the
dipstick. Top up if necessary as described on pages 5 & 6.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF A
COMPRESSED AIR SUPPLY.

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CLEAN THE COMPRESSOR AIR FILTER (MONTHLY)
The air filter must be examined monthly or more often in dusty conditions.
1. Remove the securing wingnut.
2. Lift off the top cover to expose the
filter element.
3. Undo the second wingnut holding
the filter in place and remove the
filter.
4. If necessary, the outer sponge
filter can be carefully cleaned in
warm soapy water.
5. Rinse and let the sponge filter dry
completely before refitting.
6. Clean the main filter element
using a soft brush or a vacuum
cleaner.
• If the main filter element is
damaged it must be replaced.
7. Refit the filters and replace the
cover, securing with the wingnuts
as above.
CHECK THE ENGINE INTAKE FILTER (3 MONTHLY/25 HOURS)
1. Unscrew the engine air intake filter
assembly and prize off the outer
cover by releasing the three small
tabs around the perimeter to
check the filter for cleanliness.
2. Tap the filter against a hard
surface to dislodge loose dirt or
blow through with compressed air.
Take care when using
compressed air and use PPE if
appropriate.

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3. Do not brush off dirt as it will be
forced into the filter fibres.
4. If necessary, the filter can be
carefully cleaned in warm soapy
water.
5. Rinse and let the filter dry
completely before refitting.
• If the compressor has been
used in a dusty environment,
the filter may need cleaning.
CHANGING THE OIL (6 MONTHLY/50 HOURS)
After the first 100 hours use, replace
the oil using CLARKE compressor oil
and CLARKE SAE30 engine oil.
Thereafter, replace the oil after every
50 hours of operation or every 6
months.
To empty the oil from the either the
compressor or engine remove the oil
drain plug shown and drain into a
suitable container.
Drain the oil when the engine is warm when it will drain quickly and
completely. A new washer should be used when replacing the drain plug.
CHECKING THE SPARK PLUG (YEARLY/EVERY 100 HOURS OF USE)
1. Pull the spark plug cap and lead
from the spark plug.
2. Use a spark plug spanner to
remove the spark plug.
3. Check for discolouration and use
abrasive to remove any build up
of carbon.
4. Check the condition of the spark
plug and replace if damaged.
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.

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5. Check the spark plug gap (a) with
a feeler gauge. It should be
between 0.6 and 0.7 mm.
• Adjust if necessary by carefully
bending the electrode.
NOTE: Spark plugs are available
from your CLARKE dealer.
6. Re-fit the spark plug taking care
not to cross thread it and tighten
half a turn after the spark plug
seats to compress the washer.
7. Refit the spark plug cap/lead.
EVERY 2 YEARS/250 HOURS
1. Carry out the oil changes.
2. Replace the spark plug and air filter.
3. Request your CLARKE dealer to replace fuel lines.
MISCELLANEOUS SPARE COMPONENTS
No Description Part No
1 Pump Assembly MK238 Complete 1370005
2 Honda Engine (type GP160HQX3) 5HP 8000002
3 Drain Cock 2000221
4 Pressure Gauge 2000171
5 Safety Valve 2000191
6 Manifold 4-way FN011276000
7 Rubber Foot FN116011006
8 Regulator FN347026000
9SparkPlug NGKBPR6ES
10 Engine Air Filter Set HS17210ZE1505
11 Recoil Starter Assembly HS28400ZDK003
12 Starter Pull-cord HS28462ZDK003

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TROUBLESHOOTING
CAUTION: DO NOT TRY TO REPAIR ITEMS IF YOU ARE UNCERTAIN. IF YOU
HAVE ANY QUERIES, CONTACT YOUR CLARKE DEALER.
PROBLEM PROBABLE CAUSE REMEDY
The compressor
fails to start
Engine switch is off. Set the engine switch to ‘on’.
No fuel. Add more fuel.
Spark plug damaged or
fouled.
Clean or change the spark
plug.
Fuel valve is closed. Open fuel valve
Choke not being used
when starting from cold.
Set choke to the starting
position shown on page 6.
Insufficient starting pull. Pull starter harder.
Engine difficult
to start
Regulator blocked/not
working placing
compressor on load.
Drain receiver. Clean or replace
regulator.
Compressor is
constantly ‘on
load’
Defective regulator.
Regulator set to a higher
pressure than the safety
valve’s operating pressure
Service or replace regulator.
Contact CLARKE service Dept.
Compressor has
stopped and
does not start.
Faulty or contaminated
carburetor.
Contact your service
department.
Compressor runs
on/off load
more frequently
that usual.
Improper or contaminated
fuel.
Check fuel or replace.
Dirt in fuel tank. Clean out tank.
Excess condensation in air
receiver.
Drain off condensation regu-
larly before use.
Leaks in system. Locate any leak using soapy
water and repair.
Unusual noise
from compressor
Unit installed on an
unsuitable base.
Compressor damaged
and needs overhaul.
Move unit to a more solid base.
Return the machine to your
nearest service agent.

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Compressor runs
‘on load’ when
no air is being
used.
Leaks in the system. Locate leaks by means of
soapy water and repair.
Compressor is
constantly ‘on
load’ and does
not reach the
set pressure.
Inlet filter blocked. Dismantle and clean or return
the machine to your service
agent.
Leaks from air receiver
fittings.
Locate and tighten any loose
connections.
Valves blocked by dirt. Contact your CLARKE service
department.
Pressure gauge defective. Replace pressure gauge.
Air leaks from cover or
drain plugs.
Empty air receiver and change
any leaking seals.
Machine too small in
relation to air consumption.
Obtain larger compressor.
Oil in the air
delivered
Sump is over full. Reduce to correct level.
Cylinder parts badly worn. Contact your service
department.
Intake air filter blocked. Clean/change air filter.
Compressor’s oil
consumption
increasing
Too much oil in compressor.
Leaks around crankcase.
Check oil level 2 or 3 minutes
after stopping.
Working temperature of
compressor too high due
to insufficient cooling.
Contact service department.
Increase ventilation to air
compressor.
Cylinder worn. Contact service department.
Intake air filter blocked. Clean or replace.
Oil level rises in
compressor
though none
has been added
Condensation in
compressor pump.
Drain oil completely to remove
condensate and contami-
nated oil.
Condensation
at air outlet
points
Compressor taking in air
which is too warm.
Obtain better fresh air supply to
compressor.
Engine cuts out
and will not re-
start.
Lack of oil has caused the
‘low oil cut-out’ to trip and
stop the engine.
Top up engine oil as shown on
page 5.
Check for low fuel level. Ensure engine has cooled and
is safe to re-fuel.
PROBLEM PROBABLE CAUSE REMEDY

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SPECIFICATIONS
Compressor
becomes too
hot.
Insufficient ventilation. See that sufficient air is supplied
to flywheel or fan of compressor
and that hot air is properly
vented.
Oil level too low (check
after stopping).
Top up oil.
Blown head gasket. Contact CLARKE service
department.
Dirt on cooling fins or inlet
filter.
Clean cooling fins and inlet filter
Unit working at too high a
pressure.
Contact CLARKE service
department.
Compressor being over-
worked and running
continuously.
Connect to a supplementary
compressor or install a larger
mode.
MODEL CFP11F
Engine type Honda GP160
Pump type MK236
Air Receiver size 2.5 litres
Max Output Pressure 100 psi
Air Output volume 9 cfm
Outlet connector 1/4” BSP Male
Dimensions (L x W x H) 510 x 370 x 470 mm
Guaranteed Sound Power Level 97 dB(A)
Weight 26.4 kg
Engine Oil capacity 0.6 L
Fuel tank capacity 1.8 L
PROBLEM PROBABLE CAUSE REMEDY

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DECLARATION OF CONFORMITY

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COMPRESSOR COMPONENTS

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COMPRESSOR COMPONENTS
ENVIRONMENTAL PROTECTION
DISPOSAL OF UNWANTED MATERIALS
One of the most damaging sources of environmental pollution is oil products.
Never throw away used oil with domestic refuse or flush it down a sink or drain.
Collect any oil in a leak proof container and take it to your local waste
disposal site. Should any components become completely unserviceable and
require disposal plastic and metal should be disposed of according to local
regulations.
No Description No Description
1 Air Filter Assembly FN317013000 21 Connecting Rod FN116091021
2 Head Bolt M6 x 45 FN014002021 22 Dipstick FN012035000
3 Cylinder Head FN116001001 23 Washer FN010072000
4 Spacer FN116060015 24 Screw M6 x 10 FN014013024
5 Heat Shield FN116060016 25 End Casing FN016032014
6 Screw M6 x 70 FN014002029 26 Screw FN014006083
7 Washer 6.5 x 18 FN014005044 27 Gasket FN116001025
8 Screw M5 x 18 FN014013042 28 Screw FN014022001
9 Elbow FN011015000 29 Eccentric Lobe FN116060005
10 Gasket FN116022009 30 Key FN116060006
11 Valve Plate FN116022100 31 Crankshaft FN116060001
12 Gasket FN116022010 32 Bearing FN033058000
13 Cylinder FN116022001 33 Seal FN010060000
14 Screw M8 x 20 FN014011064 34 Crankcase FN116060011
15 O-Ring FN010114000 35 End Casing FN116060003
16 Piston Ring Set FN216022002 36 Screw M5 x 20 FN014013046
17 Piston FN116022004 37 Screw M5 x 25 FN014013045
18 Gudgeon Pin FN116022040 38 Fan FN016060002
19 Circlip FN015001000 39 End Casing FN116060004
20 Piston Assembly FN416022004 40 Gasket Kit FN216GA0001