Clarke PIONEER 215 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS ©
PIONEER 215
AIR COMPRESSOR
1207
PIONEER 215
AIR COMPRESSOR

2
Thank you for purchasing this air compressor which is fitted with a 10 litre air
receiver.
Please read this leaflet thoroughly and carefully follow all instructions. In doing
so you will ensure the safety of yourself and that of others around you, and you
can 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
Guarantee ....................................................................................... 2
Contents ........................................................................................... 2
Safety Precautions .......................................................................... 3
Warning Symbols ............................................................................. 8
Electrical Connections ................................................................... 9
Parts Identification .......................................................................... 10
Assembly........................................................................................... 11
Preparation for use .......................................................................... 12
Operating instructions .................................................................... 14
Routine Maintenance..................................................................... 17
Troubleshooting ............................................................................... 19
Specification .................................................................................... 20
Parts Diagram .................................................................................. 21
Parts List ............................................................................................ 22
Spare Parts and Service ................................................................. 22
23

3
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:
WARNING!
When using the air compressor, you should follow basic safety precautions
including the following to reduce the risk of personal injury. Make sure that
you have read all of the instructions before using the air compressor. Keep
this booklet with the compressor for future reference by the operator. Persons
who have not read this booklet should not use the air compressor.
WARNING!
Compressed air can be dangerous. Death or serious injury could result from
improper or unsafe use of this compressor. To avoid these risks, use your
common sense and follow these basic safety instructions. Compressed air
should never be inhaled as it may contain toxic vapours or solid particles.
Always work in good ventilation, especially when spraying paints or other
toxic substances and always use a suitable face mask. Do not spray near
sources of possible ignition.
WARNING!
Attachments, hoses and accessories must meet or exceed the maximum
pressure rating of this compressor.
If low pressure parts are used, the air pressure could cause them to explode
or fly apart, resulting in serious injury. Always take great care when releasing
the pressure and connecting/disconnecting tools.
WARNING!
This compressor must be connected to a power socket that is safeguarded
by a suitable circuit breaker or fuse.
SAFETY PRECAUTIONS
22
PARTS LIST
NO. DESCRIPTION PART NO. NO. DESCRIPTION PART NO.
1 COMP. CASING COVER FN116CN0025
2 SCREW FN130203179
3 OIL DIPSTICK FN012089000
4 CASING COVER GASKET FN116120016
5 CRANKSHAFT FN279111043
6 CASING FN116120006
7 CONNECTING ROD FN116091021
8 PIN RETAINING RING FN116120011
9 GUDGEON PIN FN113113003
10 PISTON FN116022004
11 PISTON RING SET FN216022002
12 COMPLETE PISTON FN416HQ0011
13 OR 3212 (NBR) FN161280020
14 CYLINDER FN116CM0002
15 CYLINDER GASKET FN116HT0002
16 VALVE HOLDER PLATE FN416CN0003
17 HEAD GASKET FN116120014
18 HEAD FN116CN0013
19 SCREW FN014001075
20 SCREW FN014002026
21 FILTERING ELEMENT FN017007000
22I NTAKE FILTER FN317081000
23 OVERLOAD CUTOUT FN008040000
24 CONDENSER FN009200015
25 BEARING FN033082000
26 SEAL RING FN010132000
27 ROTOR FN034036000
28 WOUND CASING FN316CM1605
29 BEARING FN033005000
30 REAR COVER FN116120007
31 FAN FN116120008
32 CIRCLIP FN015083000
33 SCREW FN014002125
34 HOUSING FN116CN0019
35 DISCHARGE VALVE FN011000183
36 GASKETS SET FN216120004
50 TANK FN164CM0001V
51 WHEEL FN020006000
52 CIRCLIP FN015018000
53 HANDLE FN116022015
54 PROTECTION PANEL FN101CM0001V
55 PLUG FN111008000
56 VIBRATION DAMPER FN116011006
57 DRAIN COCK FN122020000
58 DELIVERY TUBE FN164CM0002
59 NOSE CONE FN161535012
60 LOCK NUT FN116HP0011
61 GASKET FN010041000
62 SPRING FN047113002
63 SEAL FN047113001
64 NON-RETURN VALVE FN347092000
65 L-FITTING FN011055000
66 RILSAN TUBE FN046001000
67 NIPPLE FN011080000
68 POWER CABLE FN101GA0200
69 L-FITTING FN011002000
70 SAFETY VALVE FN047206000
71 PRESSURE GAUGE FN330007000
72 PPRESSURE SWITCH FN321028000
73 NIPPLE FN011017000
74 PRESSURE REDUCER FN319228000
75 PRESSURE GAUGE FN330006000
SPARE PARTS AND SERVICE
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]

4
TRAINING: Prior to use all operators should become familiar with the instructions
in this booklet. In particular, become familiar with the ON/OFF control for
emergency stopping.
ALWAYS USE EYE PROTECTION: When operating the air compressor, always use
eye protection, and make sure that other people in the work area are also
using eye protection. Eye protectors must provide protection from flying
particles both from the front and from the side.
NEVER TOUCH MOVING PARTS: Never place your hand near any moving parts
on the air compressor or operate with the covers removed.
PROTECT YOUR SELF AGAINST ELECTRIC SHOCK: Never operate the air
compressor in wet or damp locations.
DRESS PROPERLY: Loose clothing or jewellery may be caught in moving parts.
Always tie long hair back.
KEEP VISITORS/CHILDREN AWAY: Do not allow visitors/children to handle the air
compressor or attachments and ensure that any people in the work area are
suitably dressed.
KEEP THE WORK AREA CLEAN: Cluttered areas invite accidents, clear the work
area of all unnecessary tools, debris and furniture.
DISCONNECT THE AIR COMPRESSOR: Always disconnect the air compressor from
the mains power supply and decompress before performing maintenance,
changing any parts and when not in use.
DO NOT ABUSE THE CABLE: Never pull on the cable when removing the plug
from the mains socket, or lift the compressor by the mains cable.
BREATHING QUALITY AIR: This compressor should not be used to supply breathing
quality air.
DO NOT ABUSE THE COMPRESSOR: Do not stand on the compressor.
SAFETY VALVE: Never remove or attempt to adjust the safety valve. Keep the
safety valve free from paint and other accumulations.
AVOID UNINTENTIONAL STARTING: Do not move the air compressor when it is
connected to the mains power supply. When connecting the air compressor to
the mains supply make sure the red button on top of the air compressor is in the
OFF (down) position.
SAFETY PRECAUTIONS
21
PARTS DIAGRAM

5
STORE THE AIR COMPRESSOR PROPERLY: When not in use the air compressor
should be stored in a secure, dry place out of the reach of children. Always lock
up the storage area.
PROTECT YOUR HEARING: Ear protection should be worn when operating this
compressor.
MAINTAIN THE AIR COMPRESSOR WITH CARE: If the air compressor is damaged in
any way, have it repaired by a qualified service engineer.
EXTENSION LEAD: 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.
ONLY USE PARTS AND ACCESSORIES RECOMMENDED IN THIS MANUAL: The use of
unauthorised accessories or attachments is not permitted and may result in
personal injury and damage to the air compressor. Do not attempt to repair or
modify the air compressor.
STAY ALERT: Watch what you are doing, use common sense, and do not operate
the air compressor when you are tired. The air compressor should not be used if
you are under the influence of alcohol, drugs or any medication that makes
you drowsy.
BEFORE EACH USE CHECK THE AIR COMPRESSOR AND HOSE FOR DAMAGED
PARTS: Never use the air compressor if it has been damaged in any way. Have
the air compressor repaired by a qualified service engineer. Do not use the air
compressor if the On/Off switch does not operate correctly.
HANDLE THE AIR COMPRESSOR CAREFULLY: Operate the air compressor
according to the instructions contained within this instruction booklet. This air
compressor should never be operated by children or individuals unfamiliar with
its operation.
KEEP THE MOTOR AIR VENT CLEAR: Keep the motor vent clear and free from dust,
wipe regularly to maintain an adequate supply of clean air to the air
compressor.
OPERATE THE AIR COMPRESSOR AT THE CORRECT VOLTAGE: Make sure that the
mains supply voltage is the same as the voltage shown on the rating plate.
DO NOT WIPE THE PLASTIC PARTS WITH SOLVENT: Do not use solvents or thinners
such as petrol, benzene, carbon tetrachloride or alcohol to clean the air
compressor, as these chemicals will damage the finish. With the air compressor
unplugged from the supply, use a dry cloth to wipe over the plastic casing.
SAFETY PRECAUTIONS
20
SPECIFICATIONS
Electrical Supply ..................................... 230 V, 1 Phase 50Hz
Max. Operating Pressure ....................... 10 bar / 145 psi
Motor Rating ........................................... 1.5 HP
Air Displacement .................................... 7 cuft/min
Air Receiver............................................. 10 litre
Net Weight .............................................. 23 kg
Dimensions ( L x W x H ) ......................... 410 x 340 x 630 mm
Duty Cycle .............................................. S1 (continuous)
Part No. .................................................... 2225005
Please note that the details and specifications contained herein, are correct
at the time of going to print. However, We reserve the right to change
specifications at any time without prior notice. Always consult the machine’s
data plate

6
KEEP ALL SCREWS AND COVERS TIGHTLY IN PLACE: Check the screws and covers
periodically.
ADEQUATE VENTILATION: The compressor should only be used in areas with
adequate ventilation and should not be exposed to heat, or used near
inflammable substances.
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 tank. Arrange repair with an
authorised service centre.
DO NOT MODIFY THE AIR COMPRESSOR: Do not 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.
DO NOT MODIFY THE TANK: Do not modify the tank or operate at pressures or
temperatures outside the limits stated in this booklet.
TURN OFF THE AIR COMPRESSOR WHEN NOT IN USE: When not in use, turn off the
air compressor by pressing the On/Off switch, remove the plug from the mains
supply and slowly undo the drain valve to release the pressure from the tank.
Remember to close the drain valve before storage and ensure it is fully
tightened before use.
DO NOT TOUCH HOT SURFACES: During operation, the motor, connections,
compressor body, cylinder head and tubes may get hot, please take care.
DO NOT DIRECT THE AIR STREAM AT THE BODY: Do not 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.
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 faulty
hoses.
DO NOT USE THIS COMPRESSOR TO INFLATE SMALL, LOW-PRESSURE OBJECTS: Items
such as children's toys or footballs can explode if over-inflated.
AVOID KINKING OR TRAPPING THE AIR HOSE: Always replace faulty hoses - never
attempt a repair if a leak is detected.
DRAIN TANK: Drain the tank after each use. Switch off and slowly open the drain
valve to release the air then tilt the compressor to empty condensed water.
SAFETY PRECAUTIONS
19
TROUBLE SHOOTING
With considerate use, your air compressor should provide you with long and
trouble free service. Routine checks should be made on both the electrical
supply as well as on all the compressed air lines and connections. If any fault
appears, the reason for which is not immediately obvious, we recommend that
you contact your local Clarke dealer.
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.
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7
NEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF AT
THE MAINS SUPPLY: Always use the On/Off switch on the compressor.
NEVER OPERATE WITHOUT ALL GUARDS IN PLACE: Never operate without all
guards or safety features in place and in proper working order.
NEVER OPERATE IN THE PRESENCE OF FLAMMABLE LIQUIDS OR GASES: The air
compressor produces sparks during operation.
CHECK FOR DAMAGED PARTS AND AIR LEAKS: If any part of the compressor is
damaged, it should be carefully checked to determine that it will operate
correctly and perform its intended function. Check for the alignment of parts,
damage to parts, air leaks and any other conditions that may affect its
operation. A guard or any other part that is damaged or defective should be
properly repaired or replaced by an authorised service centre. Defective
pressure switches must be replaced prior to further use of the compressor.
ONLY USE WITHIN THE RECOMMENDED OPERATING TEMPERATURE RANGE: This
compressor should only be used in an ambient temperature of between 0OC
and 25OC.
CLEANING AND CONDITION OF THE COMPRESSOR: Keep the external surfaces of
the tank clean. Avoid impact damage and do not allow the tank to come into
contact with abrasive or corrosive materials.
MOVING THE COMPRESSOR: Always transport the compressor by lifting or pulling
it with the appropriate grips or handles.
USING THE COMPRESSOR FOR PAINTING:
• Do not work in enclosed areas or near naked flames.
• Make sure 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 manufacturers instructions are followed.
MOTOR HOUSING: Do not insert your fingers or other objects inside the motor
housing to avoid physical damage or damage to the compressor.
SAFETY PRECAUTIONS
18
ROUTINE MAINTENANCE
Every six months
• Make sure that all bolts are securely tightened.
• Clean all the external parts of the compressor.
Oil
After the first 100 hours use, replace the
oil completely using Clarke SAE40
compressor oil. Then replace the oil after
every 500 hours of operation or every 6
months.
To empty the oil from the machine,
remove the oil drain plug from the
crankcase cover. See figure 12.
Non Return Valve
Examine the non-return valve, and
replace the gasket and valve if
necessary
Figure 13
Figure 14
Figure 12

8
WARNING 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 tank is filled with compressed air.
This compressor contains surfaces which may reach a high
temperature during operation. Never operate with the motor
housing removed.
Air and condensation water can burst from the compressor
when the drain plug is removed.
Wear a safety goggles and ear protectors when using this
compressor
This compressor produces a high sound level during
operation. Ear protection should be worn.
17
Figure 10
ROUTINE MAINTENANCE
IMPORTANT: Before carrying out any mainenance work, always disconnect
the compressor from the mains supply, drain the air receiver and, if
necessary, allow the machine to cool down before starting work.
Daily
Check Oil
Ensure the oil level is between the min and max marks on the dipstick. See page
11 and top-up if necessary - (use Clarke SAE 40 compressor oil, available from
your local dealer).
Drain the tank
After use, always open the drain valve to ensure that any liquid that may have
condensed, is drained off. See page 16.
Monthly
The air intake filter should be inspected on a MONTHLY basis, and more often in
dusty conditions,
To clean the air intake filter,
1 Pull the filter cover away from the
compressor as shown. See figure 10.
2 Remove the sponge filter from the
filter cover. See figure 11.
3 Clean the sponge and the filter
cover using a soft brush.
• If necessary, the sponge filter may
be gently washed in warm soapy
water,
• Rinse and allow the filter to dry
thoroughly before refitting.
5 Ensure that the filter and filter cover is
then placed back into its original
position.
• If any part of the filter is
damaged, you should obtain a
replacement. Figure 11

9
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. When replacing a detachable fuse carrier, ensure 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 ASTA approved to BS1362.
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.
16
Draining the reservoir
CAUTION! It is important to drain the reservoir before storage
1 Switch the air compressor off, by pressing down the red on/off button, and
remove the plug from the mains supply.
• Place a suitable container beneath the compressor to catch any
condensate.
2 Carefully undo the drain valve anti-clockwise until you hear a hissing noise,
this is the reservoir depressurising.
• When the gauge indicates zero and the hissing has stopped, tighten the
drain outlet nut again.
OPERATING INSTRUCTIONS
Figure 9
Drain valve

10
PARTS IDENTIFICATION
1
1 Motor housing
2 On/Off switch (red button)
3 Main reservoir pressure gauge
4 Output pressure regulator
5 Outlet tap
6 Output pressure gauge
7 Trolley handle
8 Support frame
9 Drain valve
10 Compressed air reservoir
11 Wheel
12 Pressure regulator and cut-out
13 Oil dipstick
9
10
11
7
12
13
8
2
4
36
5
15
OPERATING INSTRUCTIONS
Switching the air compressor OFF
To switch the air compressor off,
1. Close the outlet tap and press down on the on/off button (red button)
located on top of the pressure regulator
2. Switch off the mains supply and remove the plug.
• You should never leave the compressor air reservoir unattended while
under pressure, as this could be hazardous.
• Always release the pressure from the reservoir when not in use or prior
to storage, as described in 'Draining the reservoir' on page 16.
Removing a tool from the air hose
WARNING!
Always set the pressure regulator to zero before attempting to remove or
replace a tool.
1 Press down the on/off switch (red button) located on top of the pressure
regulator.
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.
Reset button
This compressor is equipped with a thermal
overload device, which operates as a
safety device to protect the motor.
When the motor overheats for any reason,
the overload cutout automatically cuts the
power thereby preventing damage to the
motor.
Wait around 5 minutes for the motor to cool
and press the reset button.
If you restart the compressor and the
overload cutout activates again, switch off
the compressor, remove the plug from the
mains and have your compressor checked by a qualified service agent.
Figure 8

11
ASSEMBLY
WARNING!
Before assembling and using the air compressor, make sure that you have
read and understood all of the safety instructions.
Installation
Take care when lifting the compressor from the packaging.
CAUTION! Do not lift the compressor from the gauge of fittings assembly. Get
assistance if necessary. This unit weighs 23 kg.
After removing the compressor from its packaging, check the integrity of the
unit, making sure it has not been damaged in transit.
Positioning the air compressor
This compressor should be positioned on a
stable, flat surface (or one with a maximum
inclination of 15O). See figure 1, and ensure
it is completely stable
Do not cover or box in the compressor.
Always position it at least 50cm from any
obstacle or wall
Make sure the compressor has good all
round ventilation.
Figure 1
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150
max
14
OPERATING INSTRUCTIONS
Switching the air compressor ON
The compressor will make a continuous loud noise when the tank is charging -
this is normal.
1. Lift the red On/Off switch located on
top of the pressure regulator.
• The compressor will charge the
main tank to 10 bar (145 psi) then
switch off.
• The compressor will restart
automatically whenever the
pressure in the main tank falls
below a certain level.
2. Check the operation of the safety
valve, under pressure daily, by pulling
the ring as shown in figure 6. Air
should be released you pull the ring and stop when the ring is released.
• If the valve does not operate as described, or if the valve is stuck, it must
be replaced by qualified service personnel before using the compressor.
WARNING!
Do not remove or attempt to adjust the safety valve.
3. Select the pressure you need using
the pressure regulator. See figure 7.
4. Open the outlet tap.
Figure 7
Figure 6
Pressure
regulator
Output pressure
gauge

12
ASSEMBLY
Moving the air compressor
Before moving the compressor, switch off and disconnect it from the mains
power supply.
• Always use the trolley handle.
• Do not lift by (or put strain on) fittings, valves or hoses.
• Take care when moving the compressor to avoid damaging the valves or
fittings.
The compressor is heavy, get assistance when lifting and moving this
compressor to avoid personal injury.
PREPARING FOR USE
Before connecting your compressor to the mains supply,
Check the Oil
1. Lift the dipstick out of the oil reservoir. See figure 2.
2. Ensure the oil level is between the min and max marks on the dipstick. See
figure 3.
• If needed top up the reservoir with Clarke SAE 40 compressor oil,
available from your Clarke dealer.
Figure 3Figure 2
13
PREPARING FOR USE
Before connecting your compressor to the mains supply, check the following:-
• The mains voltage is 230V.
• The on/off button is in the off position.
• The pressure regulator should be set at its lowest setting, i.e. turned fully
anticlockwise.
• If the machine has not been used for 24 hours or so, open the drain valve
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!
WARNING!
Before connecting any air tool, make sure you have read and fully
understood the manufacturers instruction booklet for the tool being used.
Also ensure that the 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.
1 Attach the air hose to the air outlet tap
using the hose nut. See figure 4.
• Ensure that the drain valve is finger
tight. For the location of the drain
valve, see page 10.
2 Finally, plug the mains cable into the
supply socket and switch on the power.
Hose nut
Figure 4
Figure 5
On/Off Switch