Clarke COUGAR 25 Instruction Manual

0903
COUGAR
OPERATING & MAINTENANCE
INSTRUCTIONS
COUGAR

3
Thank you for purchasing this Cougar Air Compressor which is available in two
configurations - Cougar 25, fitted with a 24 litre air receiver and Cougar 50,
fitted with a 50 litre receiver. These compressors are designed for DIY use ONLY.
Before attempting to operate the machine, please read this leaflet thoroughly
and carefully follow the 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
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.
CONTENTS Page
Safety Precautions .......................................................................... 4
Electrical Connections ................................................................... 5
Preparation for Use ......................................................................... 6
Operation ........................................................................................ 6
Shutting Down ................................................................................. 8
Maintenance .................................................................................. 8
Fault Finding .................................................................................. 10
Specifications ................................................................................ 11
Accessories .................................................................................... 11
Parts Lists and Diagrams ........................................................ 12 - 15
Parts and Service ..................................................................... 2 - 15

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:
1. COMPRESSED AIR IS DANGEROUS, NEVER direct a jet of air at people or animals,
and NEVER discharge compressed air against the skin.
2. DO NOT operate your compressor with any guards removed.
3. Electrical or mechanical repairs should only be carried out by a qualified
engineer. If problems occur, contact your Clarke dealer.
4. Before carrying out any maintenance, ensure the pressure is expelled from
the air receiver, and the machine is disconnected from the mains 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 machine.
7. DO NOT operate in wet or damp conditions. Keep the machine dry at all times.
Similarly, a clean atmosphere will ensure efficient operation. Do not use in
dusty or otherwise dirty locations.
8. Some of the metal parts can become quite hot during operation. Take care
not to touch these until the machine has cooled down.
9. Always adjust the pressure regulator to the recommended setting for the
particular spray gun or tool being used.
10. When spraying inflammable materials e.g. cellulose paint, ensure that there is
adequate ventilation and keep clear of any possible source of ignition.
11. Protect yourself. Think carefully about any potential hazards which may be
created by using the air compressor and use the appropriate protection. e.g.
Goggles will protect your eyes from flying particles. Face masks will protect
you against paint spray and/or fumes.
12. Before spraying any material always consult paint manufacturers instructions
for safety and usage.
13. Do not exert any strain on electrical cables and ensure that air hoses are not
tangled or wrapped around machinery etc.
14. When disconnecting air hoses or other equipment from your compressor ensure
that the air supply is turned off at the machine outlet and expel all pressurised
air from within the machine 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. Always ensure that all individuals using the compressor have read and fully
understand the Operating Instructions supplied.
17. Ensure that any equipment or tool used in conjunction with your compressor,
has a safety working pressure exceeding that of the machine.

5
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.
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:
Connect GREEN & YELLOW cord to terminal marked with a letter “E” or Earth
symbol “ ” or coloured GREEN or GREEN & YELLOW.
Connect BROWN cord to terminal marked with a letter “L” or coloured RED.
Connect BLUE cord to terminal marked with a letter “N” or coloured BLACK.
If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.
non-rewireable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code).
4. Replacement fuse covers can be obtained from your local dealer or most
electrical stockists.
FUSE RATING
The fuse in the plug must be replaced with one of the same rating (13 amps) and
this replacement must be approved to BS1362.
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 Clarke dealer, or CLARKE International Service Dep’t on
020 8988 7400 or e-mail [email protected]

6
PREPARATION FOR USE
NOTE: All numbered items throughout this manual refer to the parts list item number
on Pages 12 to 15
1. Remove the plastic travel plug from the oil filler hole,
on the top of the crank case, and insert the dipstick
(ref. ‘A’, Fig. 6 - p.9).
2. Check the oil level is at the correct level on the
dipstick, as shown in Fig.1. Where necessary, top up
with SAE40 Compressor Oil (Available from your local
Clarke dealer).
3. Attach the wheels, foot and handle according to the
instructions shown on the polythene bag containing
the items (Cougar 25 only).
OPERATION
NOTE: If you intend using your compressor for spraying, read also the “Helpful
Hints on Spraying” booklet - supplied with the machine.
1. Check that the mains voltage corresponds with that shown on the data sticker
on the machine.
2. Ensure that the ON/OFF knob (see Fig. 2), is in the ‘OFF’ (0) position, i.e. pushed
DOWN,then plug in and switch on at the mains supply.
Fig.1
Fig. 2

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3. To start the compressor pull UP the ON/OFF knob to the ‘ON’ (I) position - the
motor should start immediately.
Note: Should the motor fail to start immediately, it is probable that the air receiver
is already full of air. Check the tank pressure gauge (see fig. 2). If you release air,
by opening air outlet tap, the motor will start automatically once the cut-in pressure
is reached.
4. Before connecting your airline to the compressor allow it to run with the air
outlet tap completely open for 10 to 15 seconds to permit a good distribution
of the lubricating oil.
5. Close the outlet tap then connect one end of suitable air hose to the
compressor air outlet, and the other and to the equipment to be used.
Set the outlet pressure by adjusting the Output Pressure Regulator. To do this,
turn the knob clockwise to increase pressure, anti-clockwise to decrease.
Align your desired pressure setting, shown on the top of the regulator knob,
with the arrow on the casing.
Note: For most spraywork do not exceed 50 psi (unless following paint manuf-
acturer’s instructions).
For other airline equipment such as air tools, tyre gauges, staple guns, paraffin
guns etc., it may be necessary to set the operating pressure at a higher (or lower)
level.
IMPORTANT: Always refer to the accessory manufacturers’ recommendations
for optimum operating pressures for their equipment.
6. With operating pressure set, reopen the air outlet tap.
7. The Pressure Switch, located within the plastic cover beneath the ON/OFF
knob, should not require adjustment. This is an automatic device and has
been preset at the factory to stop the motor when pressure in the receiver
reaches its maximum, and to start it again when the pressure falls to the
minimum preset value. This operation is completely automatic and does not
affect the spraying process in any way. However, should problems develop
with the cut-in, cut out settings, consult your local Clarke dealer.
Fig. 3
Note:
a. If the machine pumps continuously
without cutting out then the compressor is
too small for the application/tool being used,
and damage may result. Consult your local
Clarke dealer.
b. The motor is protected by a Thermal Overload
so that if the motor overheats for any reason
-the thermal overload will trip, stopping the
motor. To restart, allow a period for the motor
to cool down, (approx 5 mins), before
pressing the Reset Button, arrowed in fig. 3.
and shown at ‘C’, fig.6

SHUTTING DOWN THE COMPRESSOR
1. To shut off the compressor, simply press DOWN on the ON/OFF knob (See
Fig. 2) . Always use this knob to shut down the compressor. NEVER USE THE
MAINS SWITCH TO STOP MOTOR.
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.
3. Before transporting your compressor or when leaving overnight, expel all air
from the receiver by opening drain valve located at the bottom of the
receiver, and shown in fig 4.
8
MAINTENANCE
A. DAILY
1. Check the oil level before you start
and top-up if necessary - (use Clarke
SAE 40 compressor oil available from
your local dealer).
2. Drain any condensate that may
have accumulated in the receiver
by unscrewing the drain plug
beneath the air receiver (fig. 4).
Fig. 5
B. PERIODICALLY
1. After the first 5 hours of running the compressor, check the cylinder head
bolts and motor housing screws and re-tighten if any have worked loose.
2. Every 50 hours (more frequently if
used in a dusty environment), clean
the air intake filter, by carefully prising
the filter from the cover as shown in
fig. 5
Clean the sponge and the inner
housing. If necessary, the sponge
filter may be gently washed in warm
soapy water, rinsed and allowed to
dry thoroughly before refitting.
If the filter is damaged, you should
obtain a replacement immediately.
Fig. 4

Fig. 7
Fig. 6
9
3. After the first 100 hours use, replace
the oil completely using Clarke SAE
40 compressor oil.
Thereafter, replace the oil com-
pletely after every 500 hours of
operation or every 6 months.
To empty the oil from the machine,
turn the screw located at the bottom
of the plastic end cover, and shown
at ‘B’ fig. 6, to the unlocked position,
denoted by the symblol .
Ensure the screw is turned back to
the locked position when completed
4. Every 500 hours of operation or every
6 months
• clean all the external parts of the compressor.
(This cleaning makes the cooling process more efficient and prolongs the life of
the machine).
• Examine the non-return valve and
renew parts if necessary (fig. 7)
(Ref: item 13, page 12 or item 8, page
13)
5. In the event of an air leak follow the
procedure below:
• Load compressor to maximum pressure
• Unplug the compressor
• With a brush and soapy water wet all ‘screwed’ air connections
• Any leaks will show through the formation of air bubbles.
WARNING
NEVER UNSCREW A CONNECTION WHILST THE AIR RECEIVER IS UNDER PRESSURE.
ALWAYS MAKE CERTAIN THAT THE TANK HAS FIRST BEEN EMPTIED.

10
FAULT FINDING
PROBLEM PROBABLE CAUSE REMEDY
The compressor
stops and will not
start again.
Bad connections. Check the electrical
connections.
Clean and tighten as
necessary.
Blown fuse
Overload cutout
switch has tripped.
Renew/Replace fuse
Switch off and wait 5 minutes
before pressing the reset button.
The compressor
does not reach
the set pressure
and overheats
easily.
Compressor head
gasket blown or valve
broken.
Wait for compressor to cool
down, disassemble the head
and replace any broken
components.
Carefully clean all sealing
surfaces before reassembling.
If in doubt contact your
nearest dealer.
NOTE: It is also possible that
you are using more air than
the compressor is capable of
delivering.
Compressor does
not start.
Air receiver charged
(see also item 1)
Open drain cock to expel air.
Compressor should start again
when pressure reduces to
approx 95 psi.
Air leaking from
the pressure switch
valve when the
compressor is not
running.
Faulty non-return
valve.
First drain the receiver
completely of air. Remove the
valve end plug, carefully clean
the valve seat and the gasket
and reassemble. See Fig 7.
Air pressure from
the regulator will
not adjust.
Replace RegulatorThe diaphragm within
the regulator body is
broken.
The compressor is
very noisy and
makes a metallic
knocking sound.
Return the machine to your
nearest service agent.
Compressor damaged
and needs overhaul.

SPECIFICATIONS
Motor ................................................................... 230V 50Hz 1Ph
Power Rating ....................................................... 1½ hp (1.1kW)
Rotational Speed................................................ 2850 RPM
Max. Pressure ...................................................... 8 bar (116psi approx)
Air Displacement ................................................ 200l/min (7 cfm approx)
Receiver .......... COUGAR 25 ............................. 24 LTR
COUGAR 50 ............................. 50 LTR
Cyl.Head Bolt Torque M6 ................................. 8.80Nm
M8 ................................. 11.7Nm
Compressor Oil ................................................... CLARKE SAE 40
Fuse Rating .......................................................... 13amps
Part No. ............ COUGAR 25 ............................. 2320910
COUGAR 50 ............................. 2320915
Duty Cycle .......................................................... S3 40%*
Should you experience any difficulties obtaining accessories, please contact the
Clarke sales department (telephone [phone]) for details of your nearest
dealer.
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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. Always consult the machine’s data plate
*Compressor motor should not run for more than 4 minutes in any 10 minute period
ACCESSORIES
Your Clarke Cougar Air Compressor can be used in conjunction with a range of
optional accessories for inflating tyres, air brushing, stapling, blowing and many
other uses. For details contact your local accessory stockist. A complete kit is
available from your Clarke dealer which is ideal for almost all applications.
Please quote part number 3110165

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COUGAR 25
No. Description Part No.
1 Reservoir FN168HQ1000V
2 End Plug FN011008000
7 Drain Valve FN022020000
8 Antivibration Pad FN020146000
9 Screw FN014013042
10 Washer FN010041000
11 Spring FN047113002
12 Valve FN047113001
13 Valve Assembly compl. FN347043000
14 Tube FN046001000
15 Connector FN199110140
No. Description Part No.
16 Pressure Gauge FN330004000
17 Adapter FN011017000
18 Pressure Regulator FN319044000
19 Tap Assembly FN322007000
21 ON/OFF & Reg. Assy FN321053000
22 Pressure Relief Valve FN047165000
23 Mains Cable FN101GA0200
24 Hand Grip FN020147000
25 Pipe FN168HQ0003
26 Elbow FN011015000
A Wheel Kit FN117HQ0001

COUGAR 50
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No. Description Part No.
1 Reservoir FN17005400V
2 End Plug FN011008000
3 Drain Valve FN022020000
4 Wheel FN020022000
5 Circlip FN015024000
6 Rubber Foot FN020093000
7 Screw FN014013042
8 Non-Return Valve Assy. FN347034000
9 Valve FN347043000
10 Spring FN047113002
11 Washer FN010041000
12 Hand Grip FN020121000
No. Description Qty Part No.
13 Tube FN046001000
14 Connector FN199110140
15 Pressure Gauge FN330004000
16 Adapter FN011017000
18 Tap Assembly FN322007000
19 Pressure Regulator FN319044000
20 ON/OFF/Regulator Assy FN321028000
21 Pressure Relief Valve FN347022000
22 Mains Cable FN101GA0200
23 Pipe Assy. FN168HQ0003
24 Elbow FN011015000

14
COMPRESSOR

15
SPARES AND SERVICING
No. Description Qty Part No.
1 Screw w/washer 1 FN216HQ0001
2 Screw 4 FN014006024
3 Dipstick compl. 1 FN216HQ0002
4 Plastic End Cover 1 FN116120002
5 Gasket 1 FB116120016
6 Shaft 1 FN116120004
7 Housing 1 FN116120006
8 Con-Rod 1 FN116058004
9 End Cap 2 FN116120011
10 Gudgeon Pin 1 FN113113003
11 Piston 1 FN116120009
12 Piston Ring set 1 FN216120003
13 Piston Assy compl. 1 FN416120002
14 GasketGasket 1 FN010133000
15 Cylinder 1 FN116121012
16 Gasket 1 FN116120013
17 Valve Block Assy. 1 FN116120100
18 Gasket 1 FN116120014
19 Cyl. Head Screw M6 2 FN014013031
No. Description Qty Part No.
COMPRESSOR
20 Cylinder Head 1 FN116120015
21 Cyl. Head Bolt M8 2 FN014001071
22 Overload protector 1 FN008040000
23 Nut 2 FN014003018
24 Capacitor 1 FN009200015
25 Bearing 1 FN033082000
26 Seal 1 FN010132000
27 Rotor 1 FN034036000
28 Stator 1 FN316121604
29 Bearing 1 FN033005000
30 End Housing 1 FN116120007
31 Bolt 3 FN014002125
32 Fan 1 FN116120008
33 Circlip 1 FN015083000
34 Plastic Cover 1 FN116121001
35 Air Filter Element 1 FN116120017
36 Nut 3 FN014003021
- Full Set of Gaskets 1 FN216120001