Clarke CHAMP 3 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0115
AIR COMPRESSOR
MODEL NO: CHAMP 3
PART NO: 2225222

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INTRODUCTION
Thank you for purchasing this CLARKE Air Compressor.
Please 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.
CONTENTS
1 x 2 HP Portable Frame Compressor
1 x Cable/Hose Storage Retaining Plate + Fixings
1 x Instruction Manual

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SAFETY PRECAUTIONS
Before using your compressor it is in your own interest to read and pay attention
to the following safety rules.
1. Compressed air is dangerous. Do not point a jet of air at persons or animals, and do
not discharge compressed air against the skin.
2. DO NOT operate your compressor with the guard removed.
3. Repairs must only be carried out by a qualified engineer. If problems occur, contact
your Clarke dealer.
4. Before carrying out any maintenance, make sure that the pressure is released from
the air receiver, 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 valve(s). 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
these until the compressor has cooled down.
9. Always set the pressure regulator to the recommended setting for the tool used.
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 cable 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 compressed 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 air 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. This compressor produces 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 carry the compressor while it is connected to
the power source, or when the receiver is filled with
compressed air.
This compressor contains surfaces which may get hot
during operation. Never operate with the motor housing
removed.
Wear safety glasses and ear protectors when using this
compressor.
This compressor produces a high sound level during
operation. Ear protection should be worn.

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ELECTRICAL CONNECTIONS
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply
through an approved 13 amp BS 1363 plug, or a suitably fused isolator switch.
If the plug has to be changed because it is not suitable for your socket, or
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely, as
insertion into a power socket could cause an electrical hazard.
If the colours of the wires in the power cable do not agree with the markings
on the plug:
• The BLUE wire must be
connected to the
terminal which is
marked N or coloured
black.
• 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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ASSEMBLY
FITTING THE HOSE STORAGE RETAINING PLATE
1. Place the bolts through the
retaining plate.
2. Place a plastic spacer tube over
each bolt.
3. Position the assembly as shown in
the picture and secure each bolt
with washers and nuts supplied.
FIT THE AIR FILTER
1. Remove the travel plug.
2. Screw the air filter into position.
• The air filter must be hand tight
only.

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FIT THE OIL FILLER CAP
1. Remove the travel plug.
2. Insert the oil filler cap.
MOVING THE AIR COMPRESSOR
• Stop the compressor and disconnect it from the power supply
before you move it.
• Always use the handle.
• To prevent damage, do not lift by (or put strain on) valves or hoses.
CAUTION: TO PREVENT INJURY, GET ASSISTANCE WHEN LIFTING THIS
COMPRESSOR.

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BEFORE USE
Before connecting your compressor to the power supply, check the following:-
• Set the ON/OFF switch to the
OFF position (pushed down).
• Make sure that the compressor
is on level ground.
• Make sure that the supply
voltage matches the voltage
shown on the data label.
CHECK THE OIL LEVEL
1. Make sure that the machine is on a level surface.
2. The oil level should be half way up
the oil sight glass.
3. If you need to add oil, remove the
oil cap and add oil to the
reservoir.
• Only use SAE30 compressor oil,
available from your Clarke
dealer Part No. 3050801

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OPERATION
If the compressor has not been used for more than 24 hours, open the drain
valve (on the bottom of the reservoir) and drain any condensate which has
collected. See page 12
ATTACHING AIR TOOLS
1. Attach the air hose to the ¼” BSP
outlet valve.
2. Attach the tool to the end of the
air hose.
3. Turn the outlet valve handle to the
ON position.
NOTE: The outlet valve is shown
without the air hose fitted for
clarity.
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.
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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CHECK THE SAFETY VALVE
To make sure that the safety valve works correctly:
1. Pull on the ring attached.
• Air will be released when you
pull on the ring and stop when
released.
2. If the valve does not operate in
this way, do not use the
compressor. The compressor must
be repaired by a qualified service
agent.
SET THE OUTPUT PRESSURE
1. Check the pressure requirement on the tool being used, it can usually be
found on the rating plate or inside the user manual.
2. Use the pressure regulator to set
the output pressure.
• Turn clockwise to increase the
pressure.
• Turn counterclockwise to
decrease the pressure.
GAUGES
1. The reservoir pressure gauge
shows the current pressure in the
reservoir.
2. The outlet pressure gauge shows
the selected outlet pressure. This
can be adjusted as shown above.
WARNING: DO NOT REMOVE OR TRY TO ADJUST THE SAFETY VALVE.

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REMOVING TOOLS FROM THE AIR HOSE
1. Push down on the On/Off button
to stop the compressor.
2. Turn the outlet valve handle to the
off position.
3. Operate the tool to depressurise
the air hose.
4. Disconnect the tool from the hose.
TURNING THE COMPRESSOR OFF
1. Follow steps 1-3 in “Removing Tools
From The Air Hose” above.
2. Disconnect the compressor from
the power supply.
3. Slowly open one of the outlet
valves to depressurise the reservoir.
• You will hear a hissing sound as
the reservoir empties.
4. Do not leave the compressor
unattended if the reservoir is pressurised.
WARNING: ALWAYS SET THE PRESSURE REGULATOR TO ZERO BEFORE YOU
REMOVE OR REPLACE A TOOL.

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DRAINING THE RESERVOIR
1. Turn the compressor off and
disconnect from the power
supply.
2. Put a container below the drain
valve to collect the condensate.
3. Open the drain valve slowly.
• Condensation will drain from
the reservoir.
4. Close the drain valve when the
reservoir has fully drained.
RESET BUTTON
This compressor has a thermal
overload device.
If the motor gets too hot, the thermal
overload device cuts the power
which prevents damage to the motor.
If the thermal overload device
operates, let the motor cool down for
5 minutes and push the reset button.
If you start the compressor and the
overload cutout operates again, stop
the compressor and disconnect from the power supply and have your
compressor examined by a qualified service agent.
CAUTION: YOU MUST DRAIN THE RESERVOIR AFTER EACH DAYS USE AND
BEFORE YOU PUT YOUR COMPRESSOR INTO STORAGE.

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MAINTENANCE
DRAIN THE RESERVOIR (DAILY)
After use, always open the drain valve to make sure that any condensate is
drained off.
CLEAN THE AIR FILTER (MONTHLY)
The air filter must be examined monthly, more often in dusty conditions,
1. Remove the filter cover from the
compressor.
2. Remove the filter cover from the
filter.
3. Remove the filter from the filter
cover.
4. Clean the sponge and the filter
cover 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.
5. Replace the filter and cover.
• If the filter is damaged, you must replace it.

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CHECK THE NON-RETURN VALVE (EVERY 6 MONTHS)
If the reservoir pressure decreases for no apparent reason, it is possible that the
non-return valve is leaking. To check,
1. Make sure that the reservoir is not
under pressure and the
compressor is switched OFF and
disconnected from the power
supply.
2. Examine the non-return valve,
and replace the gasket and valve
seal if necessary.
SPECIFICATIONS
Max Pressure 8 Bar
Vol ta ge 230 VAC (50 Hz)
Air Displacement 196 L/min.
Receiver Capacity 4 L
Fuse Rating 13 A
Dimensions (L x W x H) 510 x 375 x 478 mm
Guaranteed Sound Power Level 93 dB(A)
Weight 25.05 kg
Please note that the details and specifications contained herein, are correct at
the time of going to print. We reserve the right to change specifications at any
time without prior notice.

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TROUBLESHOOTING
CAUTION: DO NOT TRY TO REPAIR OR ADJUST THIS COMPRESSOR. 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
Clarke dealer
Compressor does
not start.
The reservoir has already fully
pressurised.
1. Open drain valve to expel air.
The compressor should start
again when pressure reduces.
Air leaking from
the non-return
valve when the
compressor is not
running.
Faulty non-return valve. 2. Check the non-return valve
(See page 14)
Air pressure from
the regulator will
not adjust.
The diaphragm within the
regulator body is broken.
1. Replace regulator
The compressor is
very noisy and
makes a metallic
knocking sound.
Compressor damaged and
needs overhaul.
1. Return the machine to your
nearest service agent.

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EXPLODED DIAGRAM
To order a part, please quote HTCHAMP3 + (Part ID number)

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PARTS LIST
NO DESCRIPTION
1Bolt M8×105
2Cylinder Head
3O Ring
4Valve Plate Subassembly
5Gasket 0.3
6Valve Gasket 0.8
7Locating Pin Ø3×6
8Cylinder Ø48
9Cylinder Gasket 1
10 Crankcase
11 Piston Ring Ø48×2
12 Oil Scraper Ring Ø48×3
13 Piston Ø48×35.5
14 Piston Pin Ø12×39.5
15 Circlip Ø14
16 Connecting Rod
17 Crank
18 Screw M8×22-left
19 Rubber Gasket
20 Breather Pipe
21 Crankcase Cover
22 Screw M5×14
23 Oil cap
24 Sealing Ring 20×40×7
25 Bearing 6204
26 Stator Subassembly
27 Rotor
28 Bearing 6202
29 Corrugated Washer 34
30 Motor Bracket
31 Bolt M5×105
32 Spring Washer 5
33 Fan
34 Circlip Ø14
35 Screw M4×14
36 Spring Washer
37 Tooth Washer 4
38 Screw M3×14
39 Spring Washer 3
40 Nut M3
41 Capacitor
42 Tooth Washer 8
43 Nut M8
44 Air Filter
45 Right-angle Connector R12
46 Base Fan Cover
47 Cover
48 Screw St3.9×16
49 Screw M5×14
50 Screw St3.9×12
51 Bolt M8×30
52 Non-return Valve
53 Nut M8
54 Reservoir 4l
55 Foot assembly
56 Drain valve ¼Inch
57 Outlet Tube
58 Nut M6
59 Spacer Tube
60 Hose Retaining Plate
61 Bolt M6×90
62 Power Cable
63 Pressure Switch
64 Manifold
65 Pressure Gauge
66 Handle Grip
67 Safety Valve
68 Quick Coupler
69 Stainless Steel Plate
70 Screw M6×14
71 Discharge Tube
NO DESCRIPTION

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY