Clarke CHAMP Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0618 Issue 3
AIR COMPRESSOR
MODEL NO: CHAMP
PART NO: 2320215 (230V) & 2320220 (110V)

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INTRODUCTION
Thank you for purchasing this CLARKE Air Compressor.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also look forward to the product giving you long and satisfactory service.
GUARANTEE
This CLARKE 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 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.
If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

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GENERAL SAFETY WARNINGS
WORK AREA
1. Keep the work area clean and well lit. Floors should always be kept clear.
Cluttered or dark areas invite accidents.
2. Keep children and bystanders away while operating a power tool.
Distractions can cause loss of control.
3. The compressor should only be used in areas with adequate ventilation
and should not be exposed to heat or used near flammable substances
PERSONAL SAFETY
1. ALWAYS stay alert, watch what you are doing and use common sense
when operating the compressor. Do not use the compressor while you are
tired or under the influence of medication, drugs or alcohol. A moment of
inattention can result in personal injury.
2. ALWAYS use eye protection when operating compressed air equipment,
and ensure that others in the work area are protected from flying particles
from the front and from the side.
3. ALWAYS protect yourself against electric shock. Never operate the
compressor in wet or damp locations.
4. NEVER over-reach. Keep your proper footing and balance at all times to
enable better control of the compressor in unexpected situations.
5. NEVER attempt any complex repairs yourself. If you have a technical
problem contact your local Clarke dealer.
6. ALWAYS store the compressor out of reach of children.
7. ALWAYS protect your hearing. Ear protection should be worn when
operating this compressor and it’s associated power tools.
8. NEVER 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.
9. NEVER insert your fingers or other objects inside the motor housing. Never
operate the compressor without the cover in place.
WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY
WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO
OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.

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10. NEVER touch hot surfaces. During operation, the motor, connections,
compressor body, cylinder head and tubes may get hot. Do not touch
these until the compressor has cooled down.
GENERAL MACHINE USE AND CARE
1. Prior to use, all operators should become familiar with the instructions in this
booklet especially the ON/OFF switch for emergency stopping.
2. ALWAYS maintain the compressor with care and keep it clean for best /
safest performance.
3. NEVER use this compressor if any part is damaged. Have it inspected and
repaired by your Clarke dealer.
4. NEVER 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.
5. NEVER abuse the power cable. Never pull on the cable when removing the
plug from the socket, or lift the compressor by the power cable.
6. ONLY use extension leads that are of an appropriate power rating and
suitable for the work environment. Extension leads must have an earth
connection. Inspect the extension lead regularly and replace if damaged.
7. 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 damaged hoses.
8. NEVER abuse the compressor by standing on it.
AIRLINE HOSES
1. ALWAYS ensure that equipment or power tools used in conjunction with the
compressor have a safe working pressure exceeding that of the machine.
2. ALWAYS keep the air hose away from any attached power tools and
ensure that the operator is not restricted by the length of the hose.
3. ALWAYS take care when a long air hose is required in the work area as it
presents a trip hazard. Coil the hose away as soon as the job is finished.
4. ALWAYS avoid kinking or trapping the air hose. Always replace faulty hoses
and never attempt a repair if a leak is detected.
5. NEVER abuse hoses or connectors. NEVER carry an air tool by the hose, or
yank it to disconnect from the air supply. Keep hoses away from heat, oil
and sharp edges. Check hoses for leaks or worn condition before use and
ensure that all connections are secure.
6. ALWAYS ensure that the air supply is turned off at the machine outlet and
any air pressure vented from within the compressor and any attached
equipment when disconnecting air hoses or other equipment.

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AIR COMPRESSOR SAFETY INSTRUCTIONS
1. ONLY USE WITHIN THE RECOMMENDED OPERATING TEMPERATURE RANGE:
This compressor should only be used in an ambient temperature of
between +5OC and +40OC (never at or below freezing temperatures).
2. 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 reservoir. Arrange
repairs with your nearest Clarke dealer.
3. BREATHING QUALITY AIR: This compressor should not be used to supply
breathing quality air.
4. SAFETY VALVE: Never remove or attempt to adjust the safety valve. The
maximum pressure is factory set. Keep the safety valve free from paint and
other accumulations.
5. AVOID UNINTENTIONAL STARTING: Do not move the compressor when it is
connected to the mains power supply. When connecting the compressor
to the power supply make sure the red button on top of the control box is in
the OFF (down) position.
6. BEFORE EACH USE CHECK THE COMPRESSOR AND HOSE FOR DAMAGED
PARTS: Never use the compressor if it has been damaged in any way. Have
the compressor repaired by a qualified service engineer. Do not use the
compressor if the On/Off switch does not operate correctly.
7. KEEP THE MOTOR AIR VENTS CLEAR: Keep the motor vents clear and free
from dust. Wipe regularly to maintain an adequate supply of clean air.
Avoid using in dusty conditions.
8. OPERATE THE COMPRESSOR AT THE CORRECT VOLTAGE: Make sure that the
mains supply voltage is the same as the voltage shown on the label.
9. ALWAYS adjust the pressure regulator to the recommended setting for the
particular spray gun or air tool being used.
10. When using the compressor for painting:
• Do not work in enclosed areas or near naked flames.
• Ensure 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 manufacturer’s instructions are followed.
11. DO NOT USE THIS COMPRESSOR TO INFLATE SMALL, LOW-PRESSURE OBJECTS:
Items such as children's toys or footballs can explode if over-inflated.
12. NEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF
AT THE MAINS SUPPLY: Always use the On/Off switch on the compressor.

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SAFETY SYMBOLS
The following safety symbols are shown on the product or it’s packaging.
Please read all of the safety and operating instructions carefully before using
this product.
Read this instruction booklet carefully before positioning,
operating or adjusting the compressor.
This compressor produces a high sound level during operation.
Ear protection should be worn.
This compressor contains surfaces which may get hot during
operation. Never operate with the motor housing removed.
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.
Risk of electric shock. The compressor must be disconnected
from the mains supply before removing any covers. Do not use
in a damp environment.
This compressor should always be started or stopped by means
of the start/stop button located on the control box. this reduces
the risk of accidental start-up.
this compressor should never be stopped suddenly by
unplugging from the mains supply. this increases the risk of
accidental start-up. never abuse the power cable

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ELECTRICAL CONNECTIONS
Before switching the product on, make sure that the voltage of your electricity supply is
the same as that indicated on the rating plate. This product is designed to operate on
230VAC 50Hz. Connecting it to any other power source may cause damage.
This product may be fitted with a non-rewireable plug. If it is necessary to change the
fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or
damaged, the plug must not be used until a suitable replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring instructions
shown below. The old plug must be disposed of safely, as insertion into a mains socket
could cause an electrical hazard.
If the colours of the wires in the power cable of this product do not correspond with the
markings on the terminals of your plug, proceed as follows.
• The wire which is coloured Blue must be connected to the terminal which is
marked Nor coloured Black.
• The wire which is coloured Brown must be connected to the terminal which is
marked Lor coloured Red.
• The wire which is coloured Yellow and Green 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
via a Residual Current Device (RCD). If in any doubt, consult a qualified
electrician. DO NOT attempt any repairs yourself.
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 a 13 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)
Earth
(Green and Yellow)

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OVERVIEW
1 Shut-off valve 8 Oil filler/ dipstick
2 Output pressure regulator 9 Anti-vibration feet
3 On/Off switch 10 Drain valve
4 Outlet pressure gauge 11 Compressed air reservoir
5 Reservoir 12 Pressure safety valve
6 Handle 13 Pressure control switch
7 Air filter

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PREPARATION FOR USE
UNPACKING
Take care when lifting the compressor from the packaging and obtain
assistance if necessary to avoid personal injury or damage to the machine.
Always use the handle and frame.
After removing the compressor from its packaging, check that it has not been
damaged in transit. Report any damage immediately to the dealer where the
item was purchased.
POSITIONING THE COMPRESSOR
This compressor should be positioned on a stable, flat surface.
NOTE: Note: the compressor should not be operated on a steep slope or
floor angle of greater than 15O.
If the compressor is placed on a shelf or raised off the ground, it should be
secured appropriately to prevent it from falling off during use.
Do not cover the compressor. Always position it with good all-round air
ventilation.
MOVING THE COMPRESSOR
When moving the compressor;
• Always use the handle.
• Do not lift by (or place a strain on) the airline fittings or hoses.
• Take care to avoid damaging the valves or fittings.
• Always ensure it is switched off and disconnected from the power supply.
WARNING: BEFORE USING THE COMPRESSOR, MAKE SURE THAT YOU
HAVE READ AND UNDERSTOOD THE SAFETY INSTRUCTIONS.
CAUTION: NEVER TAKE THE WEIGHT OF THE COMPRESSOR BY HOLDING
THE PRESSURE CONTROL SWITCH OR OTHER ATTACHED PARTS.

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CONNECTION AND START UP
Before connecting your compressor
to the mains supply, check the
following:-
• The supply voltage must be 110V
(Champ 110 V - Part No; 2225220)
or 230V (Champ 230 V - Part No;
2225215).
• The ON/OFF switch is in the OFF
(depressed) position.
• The pressure regulator should be
set at its lowest setting, i.e. turned fully anticlockwise. (- & + arrows are
shown on the knob)
• If the compressor has not been used recently, open the drain valve shown
to drain any condensate which may have accumulated. When clear,
close the 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.
1. Connect a suitable air hose to the
compressor outlet and the other
end to the equipment to be used.
2. Attach the air hose to the air
outlet using the hose nut as
shown.
3. Ensure that the drain valve is
closed finger tight as above.
4. Ensure the ON/OFF switch is in the
OFF position, i.e. pushed down, then plug in the machine and switch ON at
the mains supply.
WARNING: BEFORE CONNECTING ANY AIR TOOL, MAKE SURE YOU HAVE
READ AND FULLY UNDERSTOOD THE MANUFACTURER’S INSTRUCTION
BOOKLET FOR THE AIR TOOL BEING USED. ALSO ENSURE THAT THE AIR
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.

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CHECKING THE OIL
1. Remove dipstick as shown and check the level of oil is between the MAX
and MIN marks as shown below. If not, top up to the correct level with
Clarke SAE40 compressor oil available from your Clarke dealer.
2. After the first 5 working hours, replace the oil as described under
MAINTENANCE on page 15.

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OPERATING INSTRUCTIONS
STARTING THE COMPRESSOR
1. Pull the ON/OFF switch shown in
Fig 5, upwards to start the
compressor. The motor should
start immediately and run while
the reservoir is being pressurised.
2. When starting the compressor for
the first time and before
connecting it to the airline
equipment, leave it running for
about 10 minutes to permit a
good distribution of lubricating oil.
3. Check the operation of the safety valve under pressure on a daily basis by
pulling the ring shown above. Air should be released while the ring is pulled
and stop when the ring is released.
• If the valve does not operate as described, or is stuck, it must be replaced
by your Clarke dealer before the compressor is used.
• Observe that the compressor stops automatically when the maximum
pressure of 10 bar is reached. The pressure is indicated on the reservoir
pressure gauge shown below.
WARNING: NEVER REMOVE OR ATTEMPT TO ADJUST THE SAFETY VALVE.

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WORKING PRESSURE ADJUSTMENT
Different air tools which can be
powered by the compressor will
require different operating pressures
to work efficiently.
1. Adjust the air pressure delivered
using the pressure regulator.
2. Turn the pressure regulator knob
clockwise to increase pressure &
anti-clockwise to decrease it.
• The pressure setting will be
displayed by the outlet pressure
gauge shown.
• Use the regulator locking ring to set the pressure.
NORMAL RUNNING
The compressor is fitted with a combined ON/OFF pressure control switch
whose cut-in and cut-out pressures are factory set.
When the reservoir pressure falls below the minimum threshold setting, (about
2-bar lower than the maximum pressure) the compressor will re-start and will
cut out when the maximum reservoir pressure is achieved.
Note: If the machine pumps continuously without intermittently switching on
and off, the compressor is too small for the demand of the application/tool
being used and damage could result. Consult your Clarke dealer.
OVERLOAD CUT-OUT
The compressor is fitted with an
overload cutout to protect the motor
in the event of overheating.
If the device should trip out and shut
down the compressor, wait around 5
minutes for the machine to cool
down before re-setting the device by
pressing the overload re-set button
shown.
If, having re-started the compressor,
the overload cutout trips again, set the main switch to the OFF position, unplug
the machine and consult your Clarke dealer.
SHUTTING DOWN AND STORAGE
Press the red ON/OFF switch to shut off the compressor.

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Never stop the compressor by unplugging it from the power supply. It should
be turned off as above.
After use, set the outlet pressure back to zero.
Trigger all equipment (tools, spraygun etc) to release any air pressure from the
air hose before disconnecting the hose from the compressor.
Before transporting or storing the compressor, release all air pressure from the
reservoir by opening the drain valve.
• It may be desirable to place a container beneath the compressor to catch
any condensate.
Avoid storing the compressor in an environment where the temperature is
likely to drop to or below freezing.

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MAINTENANCE
DAILY / WEEKLY / BEFORE USE
1. Drain any condensate by opening the drain valve fitted to the receiver. As
soon as air starts to flow out, close the drain cock.
2. Inspect the compressor for damaged parts or for any loose screws or bolts.
3. Check the oil level is between the MAX & MIN marks on the dipstick & top
up if necessary. (Use Clarke SAE40 compressor oil). Ensure the oil does not
drop below the minimum level to avoid damage to the machine.
PERIODICALLY
1. Check and clean, if necessary,
the sponge air inlet filter element
shown. The filter may be removed
from the plastic cover and gently
washed in warm soapy water.
Rinse and allow to dry thoroughly
before re-fitting.
• This should be done more
frequently if the compressor
operates in a very dusty area.)
2. Keep the cooling fins clear of dust if the machine is being used in a dirty
workplace.
6 MONTHLY/500 HOURS
If the oil has become contaminated it should be replaced as follows;
1. Remove the dipstick and unscrew the drain plug from the crankcase cover
and drain the oil into a container.
NOTE: This operation is best performed when the machine is warm so as
to encourage the oil to drain easily.
WARNING: ALWAYS VENT THE AIR RECEIVER BEFORE CARRYING OUT ANY
ADJUSTMENTS, SERVICING OR MAINTENANCE. NEVER UNSCREW A
CONNECTION WHILST THE AIR RECEIVER IS UNDER PRESSURE. ALWAYS
ENSURE THE RECEIVER HAS BEEN VENTED.
CAUTION: NEVER OPERATE THE COMPRESSOR WITHOUT THE SPONGE
FILTER FITTED, AS FOREIGN MATTER COULD SERIOUSLY DAMAGE THE
INTERNAL COMPONENTS. IF DAMAGED, THE FILTER SHOULD BE
REPLACED.

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2. Replace the drain plug and re-fill
with fresh oil up to the MAX level
on the dipstick using Clarke SAE40
compressor oil.
RECOMMENDED OILS
Any compressor oil can be used which is suitable for use at room temperatures
from +5OC to + 40OC.
Clarke SAE40 Compressor Oil (1 litre) is available from your Clarke dealer (part
no 3050810). See the Clarke catalogue for other consumables.
ENVIRONMENTAL PROTECTION
One of the most damaging sources of environmental pollution is oil. Do not
throw away used oil with domestic refuse or flush down a sink or drain. Collect
old oil in a leakproof container and take it to your local waste disposal site.
EVERY 2 YEARS
Check the non-return valve shown
and if necessary, replace the gasket
(O-ring).
CAUTION: PROLONGED EXPOSURE TO USED OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED OIL.

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IMPORTANT: The use of parts other
than Clarke replacement parts
may result in safely hazards,
decreased tool performance and
will invalidate your warranty.
NOTE: Your Clarke compressor
has been designed to
give long and trouble free
service. If, however,
having followed the
instructions in this booklet
carefully, you encounter problems, take the unit to your local
Clarke dealer.

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FAULTFINDING
SYMPTOM PROBLEM SOLUTION
Pressure drop in the
receiver.
Air leaks at connections. Run the compressor to create
maximum pressure.
Switch it off and brush a soapy
water solution onto all
connections. Look carefully for
air bubbles being forced out.
Tighten any connections where
bubbles are seen.
If problem persists, contact your
Clarke dealer.
Compressor stops
and will not start
again.
Bad electrical connections.
Blown fuse.
Overload cut-out switch
has tripped.
Check connections. Clean and
tighten as necessary.
Renew/replace fuse.
Switch off machine and wait 5
minutes before pressing reset
button.
Compressor fails to
reach the set
pressure and
overheats easily.
Compressor head gasket
failed or valve damaged.
Stop the compressor and
contact your Clarke dealer.
Compressor does not
start.
Air reservoir already pressurised. Open drain valve and expel
some air. Compressor should re-
start when the reservoir pressure
trips the pressure control switch
at approx 95 psi.
Air found leaking
from the pressure
switch valve when
the compressor is not
running.
Faulty non-return valve. Vent the receiver completely of
air. Remove the valve end plug,
carefully clean the valve end
seat and gasket, then re-
assemble. See Fig 11.
Pressure switch valve
leaks after the
compressor has
been running for
more than about a
minute
Failure of the empty-start valve
in pressure control switch.
Replace the pressure control
switch
Air pressure cannot
be adjusted at the
regulator
Broken diaphragm inside the
regulator body.
Replace regulator.

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In the event that any of the above situations arise, requiring the dismantling
and overhaul of the compressor, contact your Clarke International Service
Department on 020-8988-7400.
SPECIFICATION
Please note that the details and specifications contained herein, are correct at the time
of going to print. However, Clarke International reserve the right to change
specifications at any time without prior notice.
Compressor keeps
running after the
maximum pressure
has been reached,
causing the safety
valve to activate.
Incorrect operation of the
pressure control switch.
Contact your Clarke dealer
Compressor making
undue mechanical
noise.
Compressor is damaged and
needs overhaul
Stop the compressor and
contact your Clarke dealer.
Compressor will not
run.
Motor winding burnt out. Contact your Clarke dealer
Model 110V 230V
Part No 2225220 2225215
Power supply 110V@50Hz 230V@50Hz
Dimensions (L x W x H) 540 x 300 x 388
Weight 23.2 kg
Fuse rating 13 amps
Air receiver capacity 2.4 litres
Duty cycle S1 (continuous)
Max Air pressure 10 Bar/145 psi
Max flow rate 217L/min (7.6 cu.ft/min)
Operating temperature +5o+40oC
Sound power level 95 dB LwA
Guaranteed sound power level 96 dB LwA

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PARTS DIAGRAM - COMPRESSOR