Clarke INDY OIL FREE Troubleshooting guide

OPERATION & MAINTENANCE
INSTRUCTIONS 009050502
Serial/Batch No: .......................
INDY OIL FREE
AIR COMPRESSOR
INDY OIL FREE
AIR COMPRESSOR

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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 machines data plate
THIS PAGE LEFT INTENTIONALLY BLANK
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Thank you for purchasing this Clarke Indy Air Compressor. Before
attempting to operate the machine, please read this instruction manual
thoroughly and carefully follow all directions given. This is for your own
safety and that of others around you, and also to help you achieve long
and trouble free service from your compressor.
Guarantee
This product is guaranteed against faults in manufacture for 12
months from purchase date. Please keep your receipt as proof of
purchase. This guarantee is invalid if the product has been abused
or tampered with in any way, or not used for the purpose for which
it is intended. The reason for return must be clearly stated. This
guarantee does not affect your statutory rights.
Contents Page
Safety Precautions................................................................ 4
Electrical Connections......................................................... 5
Operating Instructions.......................................................... 6
General Arrangement ......................................................... 7
Paint Spraying Hints .................................................. 8,9 & 10
Routine Maintenance........................................................ 11
Fault finding......................................................................... 12
Technical data ................................................................... 13
Shutting down the compressor......................................... 13
Parts List & Diagrams - (JS Spraygun) ...................... 14 & 15
Parts List & Diagrams - ( Compressor) ..................... 16 & 17
Declaration of Conformity ................................................ 18
INDY AIR COMPRESSOR
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Safety Precautions
WARNING!
Compressed air can be dangerous.
Follow these safety instructions carefully.
• Never direct a jet of compressed air at people or animals, or spray
paint towards people or animals.
• Use appropriate protective equipment, such as Clarke safety-
goggles or glasses, dust masks, ear defenders etc. when using
compressed air tools.
• Air compressors work at high pressure. Inspect equipment and hoses
regularly, checking for any damage or leaks. Have any damage
properly repaired before using the machine again.
• Do not operate the compressor with any guards removed.
• Donot adjustor tamperwith thesafety valvein anyway.Themaximum
working pressure (115 psi - approximately 8 bar) is clearly marked on
the compressor and air receiver.
• The compressor will become hot during operation. Do not touch the
cylinder head or discharge pipe while the compressor is in use.
• Always close the air outlet valve and release any pressure from the air
hose (by operating the tool briefly) before disconnecting any hoses
or tools.
When paint spraying:
• Always wear a suitably approved breathing mask when paint
spraying, to protect against inhalation of paint spray or fumes.
Anairfeed mask maybe required whenspraying some typesof paint.
If in doubt, check the paint manufacturers instructions.
• Make sure there is adequate ventilation. Do not spray in confined or
enclosed areas.
• Manypaints areflammable.Do notsmoke whilespraying orpreparing
paints, or spray near a naked flame or heat source.
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PARTS LIST (Compressor)
No Description Qty No Description Qty
1 Screw 4 28 Hose Adapter 1
2 Compressor Head 1 31 Hose 1
3 Gasket 1 33 Pressure Gauge 1
4 Valve 1 34 Disk 1
5 Valve Plate 1 35 Screw 1
6 Gasket 1 36 Filter retainer 1
7 Screw 1 37 Air Filter 1
8 Piston Segment 1 38 Motor 1
9 Con-Rod 1 39 Bearing 1
10 Screw 4 40 On/Off Press Rel Valve 1
11 Crankcase 1 41 Pressure Gauge 1
12 Eccentric Shaft 1 42 Valve Block 1
13 Screw 4 43 Hose adapter 1
14 Base Plate 1 44 Pressure Rel Valve 1
15 Screw 1 45 Olive 1
17 Fan 1 46 Hose Connector 1
18 Motor Shaft 1 47 Hose 1
19 Capacitor 1 48 Hose Clamp 1
20 Plastic Cover 1 49 Hose 1
21 Bayonet Conn Nut 1 50 Power Cable 1
22 Tap 1 51 Cable 1
25 Pressure Regulator Assy 1

Electrical Connections
230 Volt models:
Connect the mains lead to a standard 230 Volt (50Hz) electrical supply through
an approved BS1363, 13amp plug or a suitably fused isolator switch.
110 Volt models:
Connect the mains lead to a suitable 110 Volt (50Hz) electrical supply through an
approved plug or a suitably fused isolator switch. If using a portable 110 Volt
transformer make sure it has a rated capacity sufficient to take the load of the
compressor (See Data Plate).
All models:
We recommend that the compressor is connected to the mains supply through a
Residual Current Device (RCD).
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 cord 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
230 Volt models:
If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.
non- rewirable) please note:
1. The plug mustbethrown away ifcutfrom the electriccable.There is adanger
of electric shock if it is subsequently inserted into a socket.
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.
5. The fuse in the plug must be replaced with one of the same rating (13amps)
and this replacement must be ASTA approved to BS1362.
If in doubt, consult a qualified electrician....DO NOT attempt repairs yourself
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PARTS DIAGRAM (Compressor)
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OPERATION (Numbers in brackets refer to fig 1. Page 6)
1. Check that the mains voltage corresponds to that shown on the
data sticker on the crankcase cover (5).
2. Ensure that the on/off switch (4) is set to off, position ‘O’ and all air
is expelled from the compressor by opening the outlet tap (3).
3. Plug in and switch on the main electrical supply.
4. To start the compressor, switch the on/off switch (4) to on, position
‘I’, the motor should start immediately.
5. Before connecting your airline to the compressor, allow it to run
for a few seconds with the air outlet tap (3) fully open.
6. Close the air outlet tap, DO NOT OVERTIGHTEN, connect one end
of suitable air hose to the compressor , and the other end to
the equipment being used.Set the operating pressure by adjust
ing the regulator knob (1). To do this pull the knobupwardsand
adjust by turning (clockwise to increase and anti-clockwise to
decrease). When the required pressure is reached on the pressure
gauge (2) push the knob down again to hold the setting.
NOTE: For most spray work, do not exceed 30psi (unless following
paint manufacturers instructions). For other airline equipment such
as tyre gauges, paraffin guns etc, it may be necessary to set the
air pressure at a higher or (lower) level.
7. With operating pressure set, re-open the air outlet tap.
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ACCESSORIES
Your Indy 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 further details, please contact your nearest dealer.
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PARTS LIST (JS Spraygun)
Item No Description Qty
1 Air Cap Ring 1
2 Air Cap 1
3 Air Cap 1
4 Fluid Tip 1
5 Washer 1
6 Packing Nut 1
7 Needle 1
8 Spring 1
9 Cap 1
10 Paint Feed Pipe 1
11 Container Gasket 1
13 Paint Container 1
14 Trigger 1
15 Pin 1
17 Nipple ¼” 1
18 Quick Release Nut 1
PARTS & SERVICE TEL: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]

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INDY SPRAY OUTFIT
1. Pressure regulator knob. 6. Mains Lead.
2. Pressure gauge. (not shown)
3. Air outlet tap. 7. Recoil air hose.
4. On/Off switch. 8. JS Spraygun.
5. Crank case cover.
PARTS DIAGRAM (JS Spraygun)
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PAINT SPRAYING HINTS
WARNING
NEVER attempt to spray unless you are wearing suitable, approved
respiratory and eye protection.
REMEMBER that some modern paints require specialist respiratory
protection...always consult the paint manufacturers instructions.
1. GENERAL PREPARATION
a. Ensure that the area in which you will be spraying is clean and dust free.
b. Connect spray gun to compressor via suitable flexible hose.
c. With no paint in spray gun, test system for air leaks.
d. Cover adjacent pieces of equipment to prevent overspray. Mask areas
of the article not to be sprayed.
e. Ensure surface to be painted is clean, dry and free from oil and dust.
Check paint manufacturer’s instructions for any special surface
preparation required.
REMEMBER - TIME SPENT PREPARING SAVES TIME SPENT FINISHING
2. PAINT PREPARATION
a. Achieve the correct paint viscosity. This should be done according to
paint manufacturer’s instructions, and will vary according to type of paint.
b. Having mixed the paint thoroughly in a separate container, pour into the
spray gun paint container through a fine filter.
DO NOT OVERFILL SPRAY GUN PAINT CONTAINER - three quarters full is maximum
c. It is usually best to experiment with a couple of practice spray coats on a
piece of material with the same type of surface as the article you wish to
spray, eg. metal for a car body panel, wood for a piece of furniture etc.
d. Some common problems:
PROBLEM CAUSE CORRECTION
Paint does not atomise Paint is too thick, air Addthinners.Increaseairpress.
(comes out in blobs) pressure is too low. (not above 50 psi, unless
specified by paint manuf.
Paint dries before hitting Paint is too thin. Air Add more paint.
surface, leaving it dry pressure is too high Reduce air pressure
with a rough texture
Finish is pitted like Air pressure too high Reduce air pressure,
Orange peel or spray too close to increase distance between
work gun and work.
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TECHNICAL DATA
Model Indy Air - (Oil Free)
Maximum Air Pressure 115 PSI
Air Displacement 3.5 CFM
Motor ½ HP
Voltage 230 vac & 110 vac
Weight 9.6 kg (Packed)
Part Number
Air Indy 110 Vac 3230071
Part Number
Air Indy 230 vac 2320070
Dimensions (mm) 340 x 150 x 270
SHUTTING DOWN THE COMPRESSOR
1. Ensure that the on/off switch is in the off -’O’ position.
NEVER USE THE MAINS SWITCH TO STOP THE MOTOR.
2. Depress equipment trigger (spraygun) to release air from the hose and
compressor before disconnecting from the machine.
3. Switch off and remove mains.
SHUTTING DOWN THE COMPRESSOR

For a professional looking finish paint must be thinned. If manufacturers recom-
mendations on thinning are not available, the following can be used as a
general guide.
Water based paints (emulsions) 10-20% water.
Oil based paints (gloss) up to 10% thinners.
Cellulose paints up to 50 % cellulose thinners.
HANDLING THE GUN
the first requirement for a good resultant finish is the proper handling of the gun.
The gun should be perpendicular to the surface being covered and moved par-
allel with it. The stroke should be started before the trigger is pulled and likewise ,
released before the stroke is ended. This gives accurate control of the gun and
material.
The distance between the gun and the surface to be covered should be 6 to 12
inches depending on the material and atomising pressure. The material depos-
ited should always be even and wet. Lap each stroke over the preceding stroke
to obtain a uniform finish.
NOTE: To reduce overspray and obtain maximum efficiency, always spray with
the lowest possible atomising air pressure.
PAINT SPRAYING HINTS Cont
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PAINT THINNING
CAUTION Do not attempt any repair or adjustment if you are uncertain as
to how it should be done. If you have any queries, contact your local
CLARKE Dealer.
FAULT FINDING
With considerate use, your CLARKE Air Compressor should provide you with long
and trouble free service. Routine checks should be made on both the electrical
supply as well as the compressed air lines and connections. If any fault appears,
the reason for which is not immediately obvious, please contact your local
CLARKE Dealer.
PROBLEM PROBABLE CAUSE REMEDY
Motor windings
burnt out. Contact your local dealer
for a replacement motor.
Switch off and wait 5
minutes before switching on.
Overload cutout
switch has tripped.
The compressor
stops and will
not start again.
Bad connections. Check electrical
connections.
Clean and tighten as
necessary.
The compressor
does not reach
the set pressure
and overheats
easily.
Compressor head
gasket blown or
valve broken.
Contact your CLARKE
dealer.
Replace Piston (contact
your CLARKE dealer)
Compressor
does not start. Compressed air i cylinder head Turn the air outlet tap off and
disconnect hose (if fitted).
Open the outlet tap and
expel air from cylinder
head. Restart
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1) Immerse only the front end of the gun until solvent just covers the fluid
connection.
2) Use a bristle brush and solvent to wash off accumulated paint.
3) Do Not submerge the entire spray gun in solvent because:
a) The lubricant in the leather packings will dissolve and the packings will dry
out.
b) The lubricant at wear surfaces will dissolve causing harder operation and
faster wear.
c) Residue from dirty solvent may clog the narrow air passages in the gun.
4) Wipe down the outside of the gun with a solvent dampened cloth.
5) Lubricate the gun daily. Use a light machine oil on:
a) fluid needle packing.
b) Air valve packing.
c) Fan control packing.
d) Trigger pivot point.
Coat the fluid control spring with vaseline.
6) Caution: Never use lubricants containing silicone. This material may cause
contamination, leading to finish defects.
SPRAY GUN MAINTENANCE
PAINT SPRAYING HINTS Cont ROUTINE MAINTENANCE
IMPORTANT
Before attempting to service or carry out any maintenance or repairs on your
Indy air compressor, always ensure that the unit is disconnected from the main
electricalsupply,i.e. mains plugremoved,alsoensurethatallair has beenexpelled
from the cylinder head.
NOTE: After the first 5 hours operation, check that all nuts and bolts are tight,
paying special care to the compressor head and crankcase.
To keep your Indy compressor working efficiently, periodic servicing is necessary,
follow the service schedules below.
Monthly:
Remove and clean the air intake filter element (37) (this should be carried
out more frequently if the compressor is used in dusty atmospheres).
With SPONGE ELEMENTS gently blow clean with compressed air or wash
in solution of household detergent.
Rinse and dry thoroughly before re-fitting.
Remember that a dirty filter prevents adequate aspiration and adversely
affects the efficiency of your compressor.
WARNING:
Never operate the compressor without the air intake filter fitted.
YEARLY or 1000 HRS:
Replace the air intake element.
EVERY 2 YEARS or 2000 HRS:
Check and clean the intake and delivery valves.
WARNING:
When components are removed for servicing always take the
opportunity to fit new seals.
In the event of an air leak, follow the procedure below:-
a) Load the compressor to the maximum pressure.
b) Un-plug the compressor from the main electrical supply.
c) Using a brush and soapy water, wet all ‘’screwed’’ connections. (Take
care not to wet any electrical component).
d) Any leaks will show up through the formation of bubbles.
NEVER UNSCREW A COMPRESSOR CONNECTION WHILE THE MACHINE IS UNDER
PRESSURE. ALWAYS MAKE CERTAIN ALL AIR IS EXPELLED BEFORE DOING SO .
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