Clarke MONZA Instruction Manual

MONZA OIL FREE
AIR COMPRESSOR
MONZA OIL FREE
AIR COMPRESSOR
OPERATION & MAINTENANCE
INSTRUCTIONS 0702

For Spare Parts and Service, please contact your nearest dealer,
or CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
PARTS & SERVICE CONTACTS
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PARTS LIST (Compressor)
1 Knob 1 116005020
2 Adjusting Screw 1 116005015
3 O-ring 117 1 010024000
4 Adjusting Spring 1 116005019
5 O-ring 2021 Viton 1 010067000
6 Piston 1 116005022
7 Seal 1 116005018
8 Screw 1 014013042
9 Intake Filter 1 317028000
10 Screw 4 014013027
11 Head 1 116006002
12 O-ring 4081 1 010058000
13 Manifold 1 016005003
14 Screw 2 014013021
15 Head Gasket 1 116005017
16 Valve Plate 1 416005009
17 O-ring 4262 1 010057000
18 Cylinder 1 016005007
19 Piston Complete 1 416005003
20 Bearing 1 033059000
21 Fan Cover 1 116006004
22 Screw 2 014001022
23 Washer 2 116010013
24 Fan 1 116010004
25 Crankshaft 1 116010006
26 Casing 1 016010025
27 Screw 3 014002122
28 Bearing 1 033028000
29 Rotor 1 034128000
30 Wound Casing 1 316007605
31 Bearing 1 033070000
32 Balancing Ring 1 027011000
33 Screw 4 014006025
34 Vibration Foot 4 122HE0010
35 Rear Cover 1 016010016
36 Nut 3 014004001
37 Condenser 1 009200004
38 Housing 1 116006010
39 Switch 1 008006000
40 Overload Reset 1 008040000
41 Wire Holder 1 029042000
42 Power Cable 1 112GE0300
43 Clip 4 015059000
- Spray Gun (Model PS) 1 5080803
- Rubber Hose (3M) 1 3120203
No. Description Qty Part No.
Thank you for purchasing this Clarke Monza Air Compressor, designed for
DIY and light industrial use, where an output of not more than 7cfm is
required. The machine should not be run continuously, see ‘Duty Cycle’
under specifications, and is supplied wth a paint spraygun and 3 metre
hose. The Monza, unlike many other machines also delivers oil free air,
which may be very important with certain applications
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
Shutting Down ................................................................................. 7
Routing Care & Maintenance ....................................................... 8
Fault finding..................................................................................... 9
Paint Spraying Hints.............................................................. 10 & 11
Technical data.............................................................................. 12
Accessories................................................................................... 12
Parts Diagrams.............................................................................. 13
Parts List ......................................................................................... 14
Declaration of Conformity........................................................... 15
MONZA 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.
• Donotadjust ortamperwith thesafetyvalve inanyway. 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.
Anairfeedmask may berequired whenspraying sometypes of 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 DIAGRAM

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TECHNICAL DATA
Model .......................................................................... Monza - (Oil Free)
Maximum Air Pressure................................................ 115 PSI
Air Displacement........................................................ 7CFM
Motor ........................................................................... 1½ HP
Voltage........................................................................ 230 VAC
Weight ......................................................................... 10.5 kg (Packed)
Duty Cycle .................................................................. S1*
Part Number ............................................................... 2220050
Dimensions (mm)........................................................ 330x190x290
*Duty Cycle.....The Compressor may be used continuously
Should you experience any difficulties obtaining accessories, please contact the
Clarke sales department (telephone [phone]) for details of your nearest
dealer.
ACCESSORIES
Your Monza 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
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
ELECTRICAL CONNECTIONS
Connect the mains lead to a standard 230 Volt (50Hz) electrical supply through
an approved BS1363, 13amp plug or a suitably fused isolator switch.
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
If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.
non- rewirable) please note:
1. The plug must be thrown away if cut from the electric cable. There is a danger
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
Fuse Replacement
The fuse in the plug must ASTA approved to BS1362and rated at 13 amps
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MONZA SPRAY UNIT
OPERATION
Before connecting your Monza to the mains supply, check that:-
(A) The Red coloured ON/OFF Rocker switch is in the ‘O’ position.
(B) The pressure regulator on top of the machine is in the low pressure or ‘Start’
position i.e. turned fully anti-clockwise.
Connect the spraygun or the other tool which is to be used to the air outlet of the
Monza using the air hose which is fitted with quick fit adaptors at each end. An air
tightsealisformed by the rubber washer. Screw the connection together by hand,
just sufficiently for a proper seal to be made - but do not over tighten. If the face
ofa rubber seal becomes damaged,thenitmayeither be turnedover or otherwise
replaced.
NOTE:
Please refer to the manual provided wityh the spraygun for its operation and
maintenance.
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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.
PAINT THINNING
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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
paintmanufacturer’sinstructions, 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.Increaseair press.
(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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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 disconnect from the mains supply.
SHUTTING DOWN THE COMPRESSOR
Set the regulator to the desired operating pressure and then switch the machine
ON at the rocker switch. The Monza should start immediately.
However,ifatanytimeithesitatesto do this, then immediately trigger the spraygun
or tool in order to release any built up pressure.
The air pressure may, within limitations, be increased by turning the control knob
clockwise or decreased by turning it anti-clockwise.
You may need to experiment to find the setting best suited for a particular job.
When spraying paint, or similar material, it is usually best to operate at the lowest
pressure which gives a satisfactory finish.
The syphon spraygun supplied with your Monza Air Compressor is most versatile
andcanbeusedtoapplyavariety of paint material. It features two basic controls:
1. Paint control knob at the rear of the spraygun which adjusts the position of
themain needle and consequently thevolumeofpaint which can besprayed.
Minimum paint flow is achieved by having this control screwed in (clockwise)
and vice versa.
2. A fan spray control located just to the side of the spray head will alter the
shape of the fan spray.
Refer to the spraygun manual for full details.

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ROUTINE CARE AND MAINTENANCE
CAUTION
Before carrying out any of this service work, always disconnect the Monza from
themainssupply and if necessary allow the machine to cool downbeforestarting
work. Do not attempt any repair or adjustment yourself if you are uncertain as to
how it should be done.
It is important to keep the Monza Air Compressor clean and this may be done
with the help of a small soft brush and vacuum cleaner. In particular the air intake
filter should be inspected periodically, so that it is always kept free of any dirt
particles, which if not cleaned away will affect the performance of the machine.
Also, particles must not at any time be allowed to pass through into the cylinder
head as this would adversely affect the valves, including possible damage, and
entail more extensive dismantling and cleaning.
MONTHLY:
Remove and clean the air intake filter element by carefully prising off
the plastic end cover (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:
Have the intake and delivery valves checked - see your Clarkedealer.
WARNING
Never unscrew a compressor connection while the machine is under pressure.
Always make certain all air is expelled before doing so .
SPRAYGUN
Please refer to the manual provided for its operation and maintenance
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 at least
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 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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