Clarke PIONEER 220 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS
GC0511
AIR COMPRESSOR
Model No: PIONEER 220
Part Nos: 2320220(230V) & 2320221(110V)

2
INTRODUCTION
Thank you for purchasing this CLARKE 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 this 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 its intended purpose.
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 PROTECTION
Do not dispose of this product with general household waste. It must be
disposed of according to the laws governing Waste Electrical and
Electronic Equipment at a recognised disposal facility.
PARTS AND SERVICE
For parts & Servicing, 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: [e-mail]
SERVICE: [email protected]

3
CONTENTS
Introduction ............................................................................................ 2
Guarantee .............................................................................................. 2
Parts & Service ....................................................................................... 2
Technical Specification ......................................................................... 3
General Safety Precautions .................................................................. 4
Electrical Connections .......................................................................... 8
Safety Symbols ....................................................................................... 9
Overview .............................................................................................. 10
Preparation for Use .............................................................................. 11
Operating Instructions ......................................................................... 13
Maintenance ........................................................................................ 16
Troubleshooting .................................................................................... 18
Component Parts ................................................................................. 19
Declaration of Conformity .................................................................. 23
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.
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4
GENERAL SAFETY PRECAUTIONS
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 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.
10. NEVER insert your fingers or other objects inside the motor housing. Never
operate the compressor without the cover in place.
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.

5
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.

6
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. DRAIN AIR RESERVOIR: Drain the air reservoir routinely. Switch off and slowly
open the drain valve to release the air then tilt the compressor to empty
any condensed water.
10. ALWAYS adjust the pressure regulator to the recommended setting for the
particular spray gun or air tool being used.
11. 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.
12. DO NOT USE THIS COMPRESSOR TO INFLATE SMALL, LOW-PRESSURE OBJECTS:
Items such as children's toys or footballs can explode if over-inflated.
13. NEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF
AT THE MAINS SUPPLY: Always use the On/Off switch on the compressor.

7
SERVICING & STORAGE
1. TURN OFF THE COMPRESSOR WHEN NOT IN USE: When not in use, turn off
the compressor by depressing the On/Off switch, remove the plug from
the mains supply. Slowly undo the drain valve to release the pressure from
the reservoir. Close the drain valve before storage and ensure it is fully
tightened before use.
2. MOVING THE COMPRESSOR: Always transport the compressor by lifting or
pulling it with the handle.
3. CLEANLINESS AND CONDITION OF THE COMPRESSOR: Keep the external
surfaces of the reservoir clean. Avoid impact damage and do not allow
the reservoir to come into contact with abrasive or corrosive materials.
4. 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 compressor, as these chemicals will damage the finish. With the
machine unplugged from the power supply, use a dry cloth to wipe over
the plastic casing.
5. STORE THE COMPRESSOR PROPERLY: When not in use the compressor
should be stored in a secure, dry place out of the reach of children.
Always lock the storage area. DO NOT leave it exposed to the elements
and avoid direct sunlight, direct heat, rain/moisture etc.
6. 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 or damage to the compressor. Do not attempt to
repair or modify the compressor.

8
ELECTRICAL CONNECTIONS
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
Before switching the machine on, ensure that the voltage of your electricity
supply is the same as that indicated on the rating plate. These products are
designed to operate on either a domestic 230 VAC 50Hz supply (2320220) or
an earthed 110VAC 50Hz power supply (2320221). Connecting the
compressor 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.
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
If the colours of the wires in the power cable of this product do not
correspond with the terminal markings 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.
Plug must be BS1363/A approved
Earth Always fit a 13 Amp fuse.
(Green and Yellow)
Neutral Live
(Blue) (Brown)
Ensure that the outer sheath of the cable is firmly held by the clamp

9
6
7
9
3
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
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 INCORPORATES SURFACES WHICH MAY REACH A
HIGH TEMPERATURE DURING OPERATION. NEVER OPERATE WITH THE
MOTOR COVER REMOVED.
THIS COMPRESSOR MAY PRODUCE A HIGH SOUND LEVEL DURING
OPERATION. EAR PROTECTION SHOULD BE WORN.
TO REDUCE THE RISK OF INJURY, READ THE MANUAL BEFORE USE.
SAFETY SYMBOLS
The following safety symbols are present on the machine:
READ
INSTRUCTIONS
BEFORE USE
We strongly recommend that this machine is connected to the mains supply
via a Residual Current Device (RCD).
If in doubt, consult a qualified electrician. DO NOT attempt repairs yourself.

10
OVERVIEW

11
PREPARATION FOR USE
WARNING: Before using the compressor, make sure that you have
read and understood the safety instructions.
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, with one hand under the tank if required.
CAUTION! NEVER TAKE THE WEIGHT OF THE COMPRESSOR BY HOLDING
THE PRESSURE CONTROL SWITCH.
After removing the compressor from its packaging, check that it has not
been damaged in transit.
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 when moving the compressor to avoid damaging the
valves or fittings.
• Always ensure it is switched off and disconnect from the mains
power supply.
POSITIONING THE COMPRESSOR
This compressor should be positioned on a stable, flat surface.
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 surface raised off the ground, it
should be secured appropriately to prevent it from falling off during use.
Do not cover or box in the compressor. Always position it with good all-round
air ventilation.
CONNECTION AND START-UP
Before connecting your compressor to the mains supply, check the
following:-
• The correct mains supply voltage is available for the product; either
230V (2320220) or 110V (2320221).

12
• 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 in Fig 1 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 manufacturer’s instruction booklet
for the air 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 8 bar, the pressure
regulator must be used to adjust the output pressure.
1 Connect a suitable air hose to the
compressor outlet and the other
end to the equipment to be used.
Attach the air hose to the outlet
connector using the quick-release
fitting as shown in Fig 2.
2. Plug in the machine and switch ON
at the mains supply.
Fig 2
Fig 1

13
CHECKING THE OIL
1. Remove dipstick and check the level of oil is
between the MAX and MIN marks as shown
in Fig 3. If not, top up to the correct level
with Clarke SAE40 compressor oil.
2. After the first 5 working hours, replace the oil
as described under MAINTENANCE on page
16.
OPERATING INSTRUCTIONS
STARTING THE COMPRESSOR
1. Pull the ON/OFF switch UP to start the
compressor as shown in Fig 4.
• The motor should start immediately, and
run, while the tank (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.
• Observe that the compressor stops
automatically when the maximum
pressure of 8 bar is reached. The pressure
is indicated on the tank pressure gauge
shown in Fig 6.
Fig 3
Fig 4

14
3. Check the operation of the safety valve
when under pressure on a daily basis by
pulling the ring shown in Fig 5. Air should be
released while the ring is pulled out 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 your Clarke dealer before
the compressor is used.
WARNING: Do not remove or attempt to
adjust the safety valve.
WORKING PRESSURE ADJUSTMENT
Different air tools which can be
powered by this compressor will
require different operating pressures
to work efficiently.
Adjust the air pressure delivered
using the pressure regulator as
follows:
1. Pull the cap of the regulator
towards you.
2 Turn the pressure regulator knob
clockwise to increase pressure
and anticlockwise to decrease
pressure.
• The pressure setting will be displayed by the outlet pressure gauge shown
in Fig 6.
3. Push the regulator cap back to lock it at the set pressure.
NORMAL RUNNING
The compressor is fitted with a combined ON/OFF pressure 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 restart and 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.
Fig 6
Fig 5

15
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 resetting the device by
pressing the overload reset button
shown in Fig 7.
If, having restarted 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
1. Press the red ON/OFF switch to shut off the compressor.
• Never stop the compressor by unplugging it from the power supply.
It should be turned off as above.
2. After use, set the outlet pressure back to zero.
3. Operate the trigger of all equipment (tools, spray gun etc.) to release any
air pressure from the hose before disconnecting the hose from the
compressor.
Before transporting or storing the compressor, always release the air pressure
from the reservoir by opening the drain valve shown in Fig 1.
• It may be desirable to place a container beneath the compressor
to catch any condensate.
Note: If conditions are below freezing, it is advisable to store air tools in
a warmer place. Remember, the compressor should not be
operated at very low ambient temperatures.
Fig 7

16
MAINTENANCE
WARNING: Always vent the receiver tank 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.
DAILY / WEEKLY / BEFORE USE
1. Drain any condensate by opening the drain valve located under 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 compressor.
PERIODICALLY
1. Check the sponge air inlet filter
element shown in Fig 8 for
cleanliness. If necessary, it may be
gently washed in warm soapy
water. Rinse and allow to dry
thoroughly before refitting.
This should be done more frequently
if the compressor operates in a very
dusty area.)
CAUTION: NEVER OPERATE THE COMPRESSOR WITHOUT THE SPONGE
FILTER, AS FOREIGN MATTER COULD SERIOUSLY DAMAGE THE INTERNAL
COMPONENTS. IF DAMAGED, THE FILTER SHOULD BE REPLACED.
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 as shown in Fig 9 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.
2. Replace the drain plug and refill with fresh oil up to the MAX level on the
dipstick.
Fig 8

17
CAUTION: PROLONGED EXPOSURE TO
USED OIL IS DANGEROUS, ALWAYS
WASH YOUR HANDS THOROUGHLY
AFTER HANDLING USED OIL.
RECOMMENDED OILS
Any compressor oil can be used which is
suitable for use at room temperatures from
+ 5OC to + 45OC.
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 and if
necessary, replace the gasket (O-ring)
shown in Fig 11.
IMPORTANT: The use of parts other than
Clarke replacement parts may result in
safety hazards, poor performance and
will invalidate your warranty.
Your Clarke compressor has been
designed to give long and trouble free
service. If, however, having followed
the instructions in this booklet care-
fully, you encounter problems, take
the unit to your local Clarke dealer.
ACCESSORIES & CONSUMABLES
A wide range of airline accessories is
available, including Filter/Regulators.
Lubricators, High Pressure Hoses, Whip
Hose etc. Contact your Clarke dealer
for further information.
The use of parts other than genuine Clarke replacement parts may result in
safety hazards, decreased machine performance, and will invalidate your
warranty.
Fig 11
Fig 10
Fig 9

18
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TROUBLESHOOTING

19
In the event that any of the above situations arises, requiring the dismantling
and overhaul of the compressor, contact your Clarke International Service
Department on 020-8988-7400.
COMPONENT PARTS - RECEIVER & CONTROLS
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20
PARTS DIAGRAM - AIR RECEIVER & CONTROLS