Clarke PP10ND Installation and operation manual

Operating &M .
= . Olntenan
{S) Instruct' ce
ions
© I OD2

WARNING~
DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS
DOING SO WILL INVALIDATE YOUR GUARANTEE
SPECIFICATIONS · .
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2090940
HONDAGX120
MK101
50 litres
100psi
9cfm
1/4" BSP
940x410x780
71
99d8~A
2090960
HONDAGX120
MK101
50 litres
100psi
9cfm
1/4" BSP
101 Ox450x780
62
99d8ly,A
••See Declaration of Conformity on back cover
NOTE:
209080
HONDAGX200
MK103
50 litres
100psi
15cfm
1/4" BSP
940x410x810
70
98dB~
Specifications are correct at the time of going to print.
2090100
HONDAGX200
MK103
50 litres
100psi
15cfm
1/4" BSP
101Ox450x810
Clarke International reserves the right to change specifications at any time, as it
sees fit, in the interests
of safety or improvementin design.
Copyright: Clarke International, All rights reseNed. June.2002
1:1111i11i-------:.~:~~.::.------11i'

IReadthese safety instructions before using the equipment . I
Thank you forpurchasing this CJarke portable compressor.
The unit is powered by a Honda engine, a manualforwhich,
Is provided separately. Please refer to that manual for all
matters relating to the engine, ...starting and stopping
procedures, maintenance etc.
GUARANTEE -
This product is guaranteed against faults in manufacture for 12 months
from pur chase date. Please keep your receipt as proof of purchase.
This guarantee is i nvalid if the product has been abused or tampered
with In any way , or not used torthe purpose for which It Is Intended.
The reason for retum must be clearly stated.
This guaranteedoes not affect your statutory rights.
, CONTENTS Page
Specificati ons .. .................. .. . .. ........................ ... ....... .. .... ... ... .. . ... .............................. 2
Guarant ee ............................................... ... ...................................... ... ..................... 3
For
yo ur Own Safety ......... .. ..................................................................................... 4
Impo rtant Ge neral No tes ............... .. .......".............................................................. 5
Ge ne ra l La you t ...................................................................................... ... ............... 6
Preparation for Use ........................................
... .............. .. .. .. .................. ... .............. 7
Starti
ng t he C ompre ssor...... .. .... .. .. ................... .... .......... .. ....................................... 8
Shutting Down
th e C ompre ss or .............................................................................. 9
Ma in tenance ........... ... .............................. .. ... . .. ... .... .............. .. ... .. ........... ... .... .. ... ... 10
Parts and S erv ic e C ontact s......................................................................... .. ........ 11
Parts
Lis tsarid Diagra ms ................................................ ... ............................ .. 12 -14
Troubleshooting ........................................
.... ............ ... .... ... .... .. ..................... .. 15 •17
Decla ration of Conformity................................... ... .. .. ........................... Back Co ver
a.- ---- ----1 (B 1--- - -- -l:l•'lai

FOR YOUR SAFEN
WARNING
Aswith all machine£Y, there are certainhazardsinvolvedwith theiroperation and use.
Exercising respect and caution will considerably lessen the risk of personal injury.
However, if normal safetyprecautions are overlooked, or ignored, personalinjury to
fhe operator, or damage lo properly may result.
It is in your own interestto read and pay attention to the following rules:
General Precautions
• ensure that a ll individuals using t he compressor hove r ead and fully un derstand the
Opera t ing Instr uct ions su pp li ed.
• stopthe engine a nd er:isure t he pressure isexpelledfrom th eairr ece i ver BEF ORE carryinQ
out any mainten(o) nce .
• en
su re that ! here is adequate ven tilati on when spraying flammable marerials e.g.
ce ll ulose point. dnd keep cle ar of any possible sour ce of ignition.
• protectyourself. lhinkcarefully obollt anypotentialhazardswhich may be created b y~
the or compressorcn:l use the qJpropriateprorecoon.e.g. Goggles 'Wif protectyour eyes
from flying particles. Face mosks wilprotectyou agcin>t po int spray and/or fumes.
• consul! point manu fact ure rs instructions for safety a nd usage. be f ore spraying
• en sure that the airsupply is tur ned off at the mach i ne outlet and all pressurised air tr'Ofl'!
1 he mach i ne and other equ ip men1 attached 1o It. is expelled B EFOR Edisconnecting ai r
hoses or
othe r equipment.
• make su re that chilcjren and animalsore ke pt weU away from th e oonip ressm and an
eq uip ment attached to it.
• ensure that any equ i pment or too l us ed In oon junctton with your compressor, h os a
safetyworking pressure
exceeding th qt of rne machine.
• direct o je t of olr qt people or animals. and NEVER dischar ge compressed airagainst
the skin . CO M PRESSED AIRCAN BE DA N GEROUS !
• le ave pressu re in the r ece iver ove rni ght or when tr an sportin g.
• o dJ u st, o rt omper with the saf ety va lv es. The maximum pressu re Is fa cto ry se t. and c lear!~
marked on the mach ine.
• oper at e in wet or dampconditions.Keepthe machine dry atall tim es . Simi larty. o cl eo
atmosphere'Milensureefficientoperation. Do not usein du sty oro th erwiSedirtylocations.
• t
ouch the machine unt il it hos cooled down ... some of lhe metal p art s con become
quite h ot during operation.
• opera te your compr essor with any guards removed .
- -- - - au-

Fire Prevention
ALWAYS
• switch the engine OFF when refueDlng.
refuel awayfrom any source of heat.
refuel in a well ventilated area.
NEVER
overfill the tonk. fill to the level specified.
smoke whilst ref uelling and ovo id smoki ng or us i ng a ndked flame near the compress
start the engine
if there is spiled fuel. Any spillage must be wi ped cl ea n and the
compressor allowed to dry before atte mpting to start t he engine.
Exhaust Gas Precautions
ALWAYS
• ensure 1tiere is adequate ventilation when us i ng t he compressor.
• position the compressorso that the exhausf is po i nted away from people or animals.
NEVER .
WARNING:
Exhaust fumes can be fatal
• use the compressor indoors or in on enclosed area.(I.e. in a warehouse. tunnel. well
hold
etc.)
IMPORTANT General Notes
• NEV ERallowan yone, notfullyfamiliar with compress o rs, to use th isequipmen t.
• DO NOT aller the engfnesettlngs .... thesesefflngs are set at the factory . Should they
n ee d re ca libration -consultyourClarke deal er
11" -------: Q'J t----- -- 1:1urlrli

Air
Filter
Pump
Oil
Dipstick
Outlet
Pressure
Regulator
Outlet
'.llillll-Pressure
Gauge
AirGovernorI
Unloading
Genie
l:l111iu! - ---- .j) - ---- -IJ;t'

PREPARATION FOR USE
A. Environmental
Ensure the compressor is sited on a firm level surface.
Ensure
the environment is dry and d ust free.
Ensure there is adequate ventilation for:
a) Air intake to compressor pum p
b) Cooling for compressor p ump
c) Engi ne exha1Jstgases.
B. Engine
Check oil and fuel levels and a visual chec k of components. Refer toengine service manual.
C. Pump
• Check o il level on the Dipstick - to l eve lmarked.
D. Fuelling
Fill with unleaded petrol. acco rding to the instructions within t he eng ine manual.
Ensure the fuel tap is set to the r eq uired position.
• Ensure Th e fuel hose and connectors are int act , in perfectly se rv iceable
condition an d there is no leakage.
Note : Always use a funnel to fill the fuel tank so as to avoid accidental spillage of
fuel. If fuel is spilled ii must be r emoved from the unit and surrounding area, before
attempting to start the engine .
E, Receiver
Drain off anycondensate. by open i ng thedrain cock (see Fig. l). Remember
to close the
cock when comp l eted .
NOTE: This should be carried out DAILY when the compressoris in constantuse.
F. Air Hose & Air Tool
Attach t he air hose to the outletusing an app ropriate connector .
NOTE: Quick fit nuts are provided . These may be removed if a 1/4"BSP is required.
Attac h the air too l/spr ay gun to t he air hose ... lfusing sn ap couplings. use
a wh
ip en d, available from your Clarke dealer.
~ ----- ----1 81-- ---- l:lilrlrli

STARTING THE COMPRE SSOR
Initial Start-u12 __ _
1. Fully open the receiver dra in cock , (located be1'Neen t he whee ls ).
2. Start theengine, according to thein st ruct ions con ta ined in theengineseNice
ma n ua l. and a ll ow to ru n for 10 minutes.
3. Aftera ten minute pe ri od , close the dra in coc k then ensure both air ou tl et
slidi ng valves are pus he d fully INWARDS to close the outlet.
Pressure will build up in the re ceiver and eventua ll y t he air govern or wi ll
ope rate so t ha tthe engine runs o ff load.The pr essu re r eg istered on the pr essure
gouge should be l OO p si.
4. Sl ide the outlettops outw ards to all ow air to escape from the out lets. and
sl ow ly tum t he pressure r egu latorcl oc kwise.Observe the p ressure gauge.
When the pressure has droppe d by approx. 20ps i. theA ir Governor/L oad
Gen ie will ope r ate and t he compressor will cu t in again .Clo se t he sliding
outlet valves
and pr es sur e in the airreceiver will once aga in increase
5. Fina ll y, stop tl1e engine and se t t he pressure regulatortozero pressure (tur ned
fully ant i cloc kwise) and a tt ac h the ai r hose and airtool.
6. Open the s li ding valv es then set the pressure re gu lator to full pressure and
check forair leaks at the tool and co nnect o rs.
Ifleaksarea pp aren t. s to p theengine and se ttheregulator to zeropr essure
(fully an ticl ock wise), p ress thetrigger of the tool to ensure no o ir ispresent
in
the airline, then r ect ify the problem be fore pr oceeding .
If no leaksore evident. set the out l et pressure to the desir ed va lue and
proceed to use the ai r too lin accordance with the manufac turers
in
st r uc tions.
Au to. Discharge Valve-I~ ~~ .,
Sliding
Val ve
Pr essu re
Regulator
1:11•-lre - -- - ------ r-u - ---- - 11.,

When starting subsequently, start the machine as follows:
l . At the beg inning of t he day. open t he drain cock and allow any condensate
to drain completely, then clo se the coc k.
2. To ease starling, ensure there is no pressure in the pump outlet manifold by
opening the Bleed Valve (See
Fig .2).
3.
Connect the airhose to one of theoutlets and the a ir tool and setthe pr essure
regulatorto zero pressure (turned fully ant iclockwise).
4. Start
the enginein accordance with the instructio ns conta i ned in the eng i ne
service ma nual, t hen close the bleed va l ve and allowp ress ureto build up .
5. When the Air Governor/L oad Gen ie hos op era t ed a nd the comp re ssor hos
gone 'off line'. sl ide t he outlet v alve oulwo rds fully then adjustthe pressure
regul ator so that the desired pr essu re is r eg is te r ed on the gauge.
6. Check forair leaks at lhe tooland connec t ors ...asabove, before proceed i ng
STOPP I NG THE COMPRESSOR
Atthe end of theda y, stop the co mpr essorin acco rda nce withthe inst ru ct ions in
t
he engine man ual. then open the drain cock.
Close the air
out let by sliding bot h va lves i nw ards.
Operate the air t ool trigger or operat ing lever etc., to ensure there Is no pressure
In the airline. then disconnect ai rli ne and too l.
WARNING!
DO NOT under any circumstances attempt to remove the air tool or disconnect
the airhose until you oresatisfied that the pressure has been relieved.
Finally. close the dra in cock .
Tok e core n ot to to uc h the engine or pump as they remain hot for s ome time
ofte r use .
1:1111·1:1i
INTERNATION AL
- ail' - - --- - -0 - ----- Cl;11•la!

MAINTENANCE
DAILY
a. Drain Air Receiver of any condensate
b.
Chec k eng i ne oil level and t op up where necessary. Ens ure the dipstick
breatherh
ole is not blocked.
c. Check p um p oil level
'----' W ~ EEKLV
o. Cl ea n Pump Air Filter
l. PPlOND
Un sc r ew pump airfilter from inlet man ifold.R emove co ver and check ai r
filter. Wash in warm soapy water if n ec essary. ri nsethoroughlyand replace
when completely dry. If it is da m aged in any way, replace. Cl ean the
plastic housi ng thoroughly before reassembly.
2. PPlSND
Turn PumpAirFilter cover and pull away to reveal paper ele ment.If badly
contaminated. r ep l ac e. Remove any loose contaminants if any then
replace.
b. Cl ean the eng ine coo li ng fins .
6 MONTHLY
R enew pump lubricating ol l.
Drain pump by removing the dr ain
screw (A rro wed in Flg.3). •
R ep l ace scr ew and top up until o il is
l eve lwith the mark on the dipstick,
using
SA E40 oil available from your
Clarke dea l er as follows:
Compressor oil - 1litre: Part No. 3050810
Compressor oil - 5 litre: Part No . 3050802
-- · - ~·i f
I l . . ..
Di~Sli.~ '.· ·· ·;
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.. !-_ ... - .... /. ~ -
'\ •. •. - ,:•\. ·-·-. -- ... ' I
In addition to the above, check the engine manual for service
schedule.
Repairs should only be carried out by a qualifiedengineer. Ifproblems
occur, contact your Clarke dea ler.
l:larlai -- -- --l ® l---- -- - 8"

PARTS LISTS AND DIAGRAMS
Spare Parts and Service Contacts
For SpareParts and Service, please contact your nearestdealer, or
CLARKE lntamaHonal, on one of the following numbers.
PARTS Be SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: Parts@clarkelntemational. com
SERVICE: [email protected]

I
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'
30--
29
~ 218 l?i
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25--~ IB'-33
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24 _,,.:<O?.-~ -32
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31
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A-1

PUMP PARTS ·
Description
l Screw
2 L
owe r Cover
3 Cosing
4 Bear
in g
5
Se al
6 Front
Cov er
7 Screw
8 Fl
ywhee l
9 Wos
her
10 Sc r ew
11 Screw
12 Wosher
13 Rear Cover
14 Oil Dipstick
15 Screw
16
Cranksha ft
17 Connecting Ro d
18 Pi ston Ri ng Kit
19
C ir clip
20
Gudgeo n Pin
21 Pis t on
22
Complete Pi ston
23
Cylinder
24
Volye Hol der Plate
25
Head
26
Filter Cart rid ge
27 Intake Fi lt er
28
Screw
29
Conveyor
30
Sc r ew
31
Complete Seal Kit
32
Manifold
33
Auto ma t ic Dis charge Va l ve
ail'
'-i3)
lOND
Part No.
014013054
11 3149015
11316700 1
033027000
010053000
1 13 149008
014013021
013160010
014005001
1131600 11
0140 1 3082
01 4005025
113149009
012036000
01 4010044
11 31 67003
11 31 4900 4
213115002
015098000
1
13 11 5025
113 11 5026
413115026
113169002
4131 49080
113149050
0
17 024000
317026000
01
4002041
113 1 50002
014006121
21 316800 1
15ND
Part No.
0140 1 3054
1 13 1 49015
1 13 1 67001
033027000
010053000
1 13149008
01401302 1
013160010
014005001
11316 0011
014013082
014005025
1 13149009
012036000
014010044
113167003
113150004
213167001
015023000
1 16 025006
11
3164009
413167006
113167002
41 3167005
11 3150022
017003000
317001000
014002041
113150002
014006121
213167002
11609 1 024
011158000
l:lilliHI

PA RT S LIS T
(>!<'.' PPlOND
PP15ND
h '
PPHlOND
PPH15ND
~
HS l 7210-ZE0-822 HSI 7210-
ZE 1-822
B
HSl 7218 -ZE 0-821 HSl 72 18-ZEl-821
~b®=
HS98079-56846 HS98079-56846
~ ~ ~ ~ -~1 "2 ~e
1. HS28442- ZH8 -003 1. HS2844 2-Z H8-003
~,~
2. HS28442-ZH8-003 2. HS28442 -Z H8-003
3. HS28462-ZH8-003 3. HS28462-ZH8-003
~~~~ -
~ '1 :~·~
lI 51
006 10 5100610
~
'-f+
I 2100177 2100177
' '\ ( l
50mm Pressu re Gaug e 20001 75
2000175
Sa fety Valve Comple te 20001 80 2000180
Dra in Cock 2000220 2000220
V-Bett 2100061
21 00063
Wheel 2100289 2100289
Whee l Retaining Clip 2100306 2 10 0306
So f1 Rubber Foo t 2100313 21
003 13
Pump Comp l ete, 1390080 (MKlOl) 1390085 (MK103)
Pulley 2100085 2100084
Engine complete
800047 ( GX 120QH) 800055 (GX200QH)
Mo nlf old 3- woy CBM45469000 CBM 45469000
Air Rece i ve r 1999705 1999705
1:1.r1ui -- -- ---;: -ld- :. --- - - --

TROUBLE SHOOTING CHART
IMP ORTAN T
1. Any re med ial wo rk t ha t may be re qu ired must be carried out by a qualif i ed eng ineer.
?. S witc h off the engine befo re rem ov ing any pa rts fr om th e compresso r.
3. Drain the Ai r Receiver before dlsmcn tt : ng a ny part of the compr essor unit's p ressure syste m.
11 . If your compresso r deve lops o fau lt do not use un til the fa u lt hos been recttfied.
5. For troublesh oot ing t he eng i ne . refer to the engine man ua l.
SYMPTOM PROBABLE REMEDY
~
Eng ine di fficult to Loa d Genie leaking Stop engine and empty air
st art (co mpress or unit Is on load receiver . Cle an or r eplace
duri ng st ar t). Load Genie
Non- r eturn valve bl ocked,
Thaw L oad Genie out (Unit mus1
posslblY frozen up .
be Ins talled In fr ost -f ree place) .
I
Co mpressor unit Load Genie defecttve.
Have Lood Genie serviced Of
co nst antly ·o n load' replaced
L oad Genie set at o pressure Adjust L oad Genie
hig h er than the safety
WARNI NG; DO NOT AD JUST
valve's opening pressu re
LOAD GEN IE ABOVE MAXIMUM
Lood Genie l ea king
WORKING PRESSURE DET AIL ED.
Com pressor Suction fitter blocked.
Change filter.
constontty 'on l oad'
Leok between compressor Tight
en connec t ion and
ood cannot attah the
bloc< and olr recetver led<s h
repa ir leak.
workin\;I pressure or
near cir receiver.
required. \,b'Jesblocked
by cit pant .
Clean or chang e valves.
dJst Q( choked 1.4).
Inspe ct ion cover or droi1 pk.Jg
E mpty oir receive r and
leoldng.
cha nge seals/plugs.
Pressure
gouge defective.
Change pressure gouge.
Unit t oo small in relation to
Usa a larger capacity
air consu mpti on.
compressor
Comp re ssor worn . H ove compressor overhau l ed or
re place it.
~ - ----- . lS ----- ClarlHt

Unusual noise fr om
Bolls loose. TQ'iten bolts.
compressor. rtywheel loose. T
igrten flywheel.
Unit instoled onon unsuitd:lle
Move unit to o moresolid base
base.
Beaings. Jj;ton rirQS or cyli1der
Rep lace wom p(lrts or change
worn.
compressor pump.
Vdve broken. Chat'lge valve po1s.
Compressor
Insufficient venttation.
See th:it sufficient <*Is suppledto
becomes t oo ho t.
flywheel a m of compra!lllOI' en:
thathot'* is properlyvented.
Oil leveltoolow(check2or 3
Fl with ol - see Page 1 0.
llnes afterstopping).
Fault In valves (rnochi"ie not
Clleck, clean/r eplace .
stopping).
Blown head gast<et (machine Checkandreplacegasket.
n ot stopping).
Dirt oncoOing fins orsuction Cleancooling
flns and suctlan
filter .
liter .
Unit working at too hi gh a Reset to correct working pressure
pessure. detoied oo unit.
Nol fuly unlooding Check
pressure unlo<:d'lg geNe .
adjust If~. check
vat.le(s).
Non-return valve par1ty blodced. Cleanorthat
out non reti...m
vcJ.Je.
Corrpressor behg Comect to o supplementary
oV9IWO!l<ed endn.rning compressor orInstall o larger
conlhuou;ty. model.

Compressor unit runs ii Lcrge omomt of condensation ir\
Drcre off c.:onderootion Reguk:rly
on and off load more ar receiver.
(Eveff dav before use).
frequently lhon usual. Leaks ir system
Localeeeks (by meCJlS of soapy
water)
and repot-.
Compressor um ruf'\S
Leaks in sys l ern.
Locate leaks (by mecr&S of
'on load' when no air is
soq:iy water) and r epcir.
beingused.
Compressor's on
Too much ol n c.ompressor.
Olecl< oi level 2 or 3mirutesafte1
consumption rising.
stopphg.
Leaks crOLf'ld crank case.
Chcnge sad Ord ln!pect
pacl<hgsufaces. Reper or
replace defecttve pats .
Working temperature of Increase ventlatlcntooi'
cOfll)ressor too high because of
compressor.
insufficien t cooling.
11 Cylh::ler worn.
Replace worn ports or serK:I
compressor pump foron
overhaul
Intakeairliterblocked.
OI nthe or delvered. &Jmp over ful. Reduce
ol to correctlevel
Cytnderwoin.
Repb::e wom ports~ send
compresso< pump tor 01
overhaul.
Intake oir filte rblocked.
Chaige a·r filter.
Oil level rises although I
Conde"""on n oa purp.
~~--
I
no ol hos been put in.
Condensation at outte t Ppi"lgnstollolionincorrect. ConUI your 1 0Cd deder
porns.
Compressor toking in or which is Obton beHElf fresti-or supply to
roowarm corrpressor.
8" --- - -----0 - -- -- l:lu1•la!

Spare Parts and Service Contacts
For Spare Parts and Service, please contact your neareat dealer , or
CLARKE lntemaHonol, on one of the following number1 .
PARTS &: SERVICE TEL: [phone]
PARTS &: SERVICE FAX: [phone]
or e-mail asfollows:
PARTS: [email protected]
SERVICE: [email protected]
aoriHi - - --___..
18
·.- - - - - -/IM'

A SELECTION FROM THE VAST RANGE OF
1:1111•111i
QUALITY PRODUCTS
AIR COMPRESSORS
FromDIY to industrial. Plus air tools,
spray guns and ac ceS$ Oties.
GENEllATORS
Pr i me duly or emergency standby
tor busir.ess, home and le is ure.
PO W ER W ASHERS
Hot anci colci, eleclrlc and eng i ne
ciriven · we /lave wr:ot you need.
WELDERS
Mig. Arc. ilg ancf Spot. From DIY lo
auto /Industrial.
METALWORKING
Dr ill s. grinders and sows for D/Y a nd
professionaluse
WOODWORKING
Saws. sanders. lallles , martisers
and efusl extraclion .
HYDRAULICS
Crones. body repa irki ts.
lransmlssianja cks far all types al
w or ks/lop use.
WATER PUMPS
Submersible. electric and engin e
driven for DI Y. agriculture and
Industry.
POWER TOOLS
Angle grinders. cordlessdrillsets.
saws and sanders.
STARTER/CHARGERS
A ll sl1es for car& commerci al use.
l:lilli:li INTERNATIONAL
•
Fo rsporeports and servic in g, please conlocl your neoresl dealer. 01 Clarke ln le<natlonoJ on
020 . 8988 . 7 400
e -m ai l: P a rt~ ar kei n t e rna ti o n al. co m e-mail: Service@:larkeintema ti ona l. com
Dil' --- -- - - --
1
.'.0 ._--- - -- l:lill
11
kli

~
j
l
j
I
I
DOC No. H076/27
Oarko htornaflonal la o tfocfng lfylo of CIOlko lntomatlonal lkritod