Clarke PP10ND Installation and operation manual

1002©
Air Compressor
PP10ND • PPH10ND • PP15ND • PPH15ND
Operating & Maintenance
Instructions

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: [e-mail]
SERVICE: [email protected]
PARTS & SERVICE CONTACTS
SPECIFICATIONS
PP10ND PPH10ND PP15ND PPH15ND
Part Number 2090940 2090960 209080 2090100
Engine Type HONDA GX120 HONDA GX120 HONDA GX200 HONDA GX200
Pump Type MK101 MK101 MK103 MK103
Air Receiver size 50 litres 50 litres 50 litres 50 litres
Max. output Pressure 100psi 100psi 100psi 100psi
Air Displacement 9cfm 9cfm 15cfm 15cfm
Outlet connectors 1/4” BSP 1/4” BSP 1/4” BSP 1/4” BSP
Dimensions (mm) 940x410x780 1010x450x780 940x410x810 1010x450x810
Weight (kg) 71 62 70 74
Sound Power Level 99dBLWA 99dBLWA 98dBLWA 98dBLWA
NOTE:
Specifications are correct at the time of going to press. Clarke International
reserves the right to change specifications at any time, as it sees fit, in the interests
of safety or improvement in design.
- 17 -
Copyright: Clarke International, All rights reserved. June, 2002
- 2 -
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: [e-mail]
SERVICE: [email protected]
Spare Parts and Service Contacts
If you have any problems using or setting up your Compressor
call the Clarke Helpline on,
020 8988 7400
Press 1 for Parts : 2 for Technical Assistance
WARNING!
DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS
DOING SO WILL INVALIDATE YOUR GUARANTEE

- 3 -
INTRODUCTION
Thank you for purchasing this Clarke portable compressor.
The unit is powered by a Honda engine, a manual for which,
is provided separately. Please refer to that manual for all
matters relating to the engine, ...starting and stopping
procedures, maintenance etc.
Read these safety instructions before using the equipment.
Guarantee ...................................................................................................................... 3
For your Own Safety ...................................................................................................... 4
Important General Notes .............................................................................................. 5
General Layout .............................................................................................................. 6
Preparation for Use ........................................................................................................ 7
Starting the Compressor................................................................................................ 8
Shutting Down the Compressor .................................................................................... 9
Maintenance................................................................................................................. 10
Parts Lists and Diagrams.............................................................................................11-13
Troubleshooting............................................................................................................. 14
Parts and Service Contacts ......................................................................................... 11
Troubleshooting............................................................................................................. 14
Specifications................................................................................................................ 17
Parts and service Contacts.......................................................................................... 17
CONTENTS Page
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.
- 18 -

- 4 -
FOR YOUR SAFETY
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:
General Precautions
ALWAYS
• ensure that all individuals using the compressor have read and fully understand the
Operating Instructions supplied.
• stoptheengineandensurethepressureis expelled from the air receiver BEFORE carrying
out any maintenance.
• ensure that there is adequate ventilation when spraying flammable materials e.g.
cellulose paint, and keep clear of any possible source of ignition.
• protect yourself. Think carefully about any potential hazards which may be created by using
the air compressor and use the appropriate protection. e.g. Goggles will protect your eyes
from flying particles. Face masks will protect you against paint spray and/or fumes.
• consult paint manufacturers instructions for safety and usage, before spraying
• ensure that the air supply is turned off at the machine outlet and all pressurised air from
the machine and other equipment attached to it, is expelled BEFORE disconnecting air
hoses or other equipment.
• make sure that children and animals are kept well away from the compressor and any
equipment attached to it.
• ensure that any equipment or tool used in conjunction with your compressor, has a
safety working pressure exceeding that of the machine.
NEVER
• direct a jet of air at people or animals, and NEVER discharge compressed air against
the skin. COMPRESSED AIR CAN BE DANGEROUS!
• leave pressure in the receiver overnight, or when transporting.
• adjust,ortamperwiththesafetyvalves. The maximum pressureis factoryset,andclearly
marked on the machine.
• operate in wet or damp conditions. Keep the machine dry at all times. Similarly, a clean
atmospherewillensure efficient operation. Donotuseindusty or otherwise dirty locations.
• touch the machine until it has cooled down...some of the metal parts can become
quite hot during operation.
• operate your compressor with any guards removed.
- 17 -

- 5 -
!
Fire Prevention
ALWAYS
•switch the engine OFF when refuelling.
•refuel away from any source of heat.
•refuel in a well ventilated area.
NEVER
•overfill the tank, fill to the level specified.
•smokewhilst refuelling and avoid smoking or using a naked flame nearthecompressor.
•start the engine if there is spilled fuel. Any spillage must be wiped clean and the
compressor allowed to dry before attempting to start the engine.
IMPORTANT General Notes
• NEVER allow anyone, not fully familiar with compressors, to use this equipment.
• DO NOT alter the engine settings....these settings are set at the factory. Should they
need recalibration - consult your Clarke dealer
Exhaust Gas Precautions
WARNING:
Exhaust fumes can be fatal
ALWAYS
• ensure there is adequate ventilation when using the compressor.
• position the compressor so that the exhaust is pointed away from people or animals .
NEVER
• use the compressor indoors or in an enclosed area. (i.e. in a warehouse, tunnel, well,
hold etc.)
Large amount of condensation in
air receiver.
Leaks in control unit or inspection
cover.
Too little pressure differential.
Compressor unit runs
on and off load more
frequently than usual.
Compressor unit runs
‘on load’ when no air is
being used.
Leaks in pipework system.
Compressor’s oil
consumption rising. Too much oil in compressor.
Sump over full.
Cylinder worn.
Oil in the air delivered.
Governor controlled unit running
off load for too long a period.
Intake air filter blocked.
Oil level rises although
no oil has been put in. Condensation in oil pump.
Piping installation incorrect.
Compressor taking in air which is
too warm.
Delivery temperature of air from
air receiver too high.
Condensation at outlet
points.
Drain off condensation AT LEAST
once a week. Locate leaks (by
means of soapy water) and
repair.
Adjust pressure switch.
Locate and repair leaks.
Check oil level 2 or 2 minutes after
stopping.
Change seal and inspect
packing surfaces. Repair or
replace defective parts.
Increase ventilation to air
compressor.
Cylinder worn.
Intake air filter blocked.
Leaks around crank case.
Working temperature of
compressor too high because of
insufficient cooling.
Semi-automatic unit: Load too
small. Convert to fully automatic
operation.
Replace worn parts or send
compressor pump for an
overhaul.
Change air filter.
Reduce oil to correct level.
Replace worn parts or send
compressor pump for an
overhaul.
Convert to automatic control.
Change air filter.
Compressor over dimensioned.
Consult your local dealer.
Obtain better fresh-air supply to
compressor.
a) Use a larger air receiver.
b) Insert an aftercooler.
- 16 -

Fig.1
- 6 -
Suction rendered difficult or
impossible at suction intake,
or the air being taken in is too
warm.
Pressure gauge defective.
Unit too small in relation to air
consumption.
Unusual noise from
compressor.
Larger fresh-air inlet.
Change pressure gauge.
Connect a supplementary
compressor or install a larger
model.
Have compressor overhauled or
replace it.
Tighten bolts.
Tighten flywheel.
Move unit to a more solid base.
Compressor worn.
Bolts loose.
Flywheel loose.
Unit installed on an unsuitable
base.
Bearings, piston rings or cylinder
worn.
Valve broken.
Bearings of electric motor worn.
Compressor
becomes too hot. See that sufficient air is supplied to
flywheel or fan of compressor and
that hot air is properly vented.
Insufficient ventilation.
Oil level too low (check 2 or 3
times after stopping).
Wrong direction of rotation.
Unit working at too high a
pressure.
Not fully unloading (Governor
control machines only).
Cooling air from flywheel fan must
blow against compressor.
Fault in valves (machine not
stopping).
Blown head gasket (machine
not stopping).
Dirt on cooling fins or suction
filter.
Check, clean/replace.
Check and replace gasket.
Clean cooling fins and suction
filter.
Reset to correct working pressure
detailed on unit.
Check pressure unloading genie,
adjust if necessary, check
valve(s).
Clean or that out non return
valve.
Connect to a supplementary
compressor or install a larger
model.
Non-return valve partly blocked.
Change valve parts.
Have motor bearing replaced.
Replace worn parts or change
compressor pump.
- 15 -
Fill with oil – see Page 10.
Compressor being overworked
and running continuously.

- 7 -
PREPARATION FOR USE
A. Environmental
• Ensure the compressor is sited on a firm level surface.
• Ensure the environment is dry and dust free.
• Ensure there is adequate ventilation for:
a) Air intake to compressor
b) Cooling for compressor pump
c) Engine exhaust gases.
B. Engine
Checkoilandfuellevelsand avisualcheckofcomponents.Refertoengineservicemanual.
C. Pump
• Check oil level on the Dipstick - to level marked.
D. Fuelling
Fill with unleaded petrol, according to the instructions within the engine manual.
• Ensure the fuel tap is set to the required position.
• Ensure The fuel hose and connectors are intact, in perfectly serviceable
condition and 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 it must be removed from the unit and surrounding area, before
attempting to start the engine.
E. Receiver
• Drainoffany condensate,byopening thedrain cock (seeFig. 1). Remember
to close the cock when completed.
NOTE: This should be carried out DAILY when the compressor is in constant use.
F. Air Hose & Air Tool
• Attach the air hose to the outlet using an appropriate connector.
NOTE: Quick fit nuts are provided. These may be removed if a 1/4”BSP is required.
• Attach the air tool/spray gun to the air hose...If using snap couplings, use
a whip end, available from your Clarke dealer.
!
TROUBLE SHOOTING CHART
IMPORTANT
1. Any remedial work that may be required must be carried out by a qualified engineer.
2. Switch off the engine before removing any parts from the compressor.
3. Drain the Air Receiver before dismantling any part of the compressor unit’s pressure system.
4. If your compressor develops a fault do not use until the fault has been rectified.
5. For troubleshooting the engine, refer to the engine manual.
REMEDY
Stop engine and empty air
receiver. Clean or replace
Load Genie
Thaw Load Genie out (Unit must
be installed in frost-free place).
Have pressure switch changed
by an electrician.
Adjust pressure switch or safety
valve.
WARNING: DO NOT ADJUST
SAFETY VALVE ABOVE MAXIMUM
WORKING PRESSURE DETAILED.
SYMPTOM
Engine difficult to
start
PROBABLE CAUSES
Load Genie leaking
(compressor unit is on load
during start).
Non-return valve blocked,
possibly frozen up.
Compressor unit
constantly ‘on load’ Pressure switch defective.
Pressure switch set at a
pressure higher than the
safety valve’s opening
pressure.
Bleed valve under
pressure switch blows
whilst compressor is
not running.
Load Genie leaking.
Bleed valve under
pressure switch blows
whilst machine is
running.
Compressor constantly
‘on load’ and cannot
attain the working
pressure required.
Load Genie leaking.
CleanLoad Genie or replace.
Suction filter blocked.
Leak between compressor
block and air receiver leaks in
or near air receiver.
Valves blocked by dirt, paint,
dust or choked up.
Inspection cover or plug
leaking.
- 14 -
Clean Load Genie or
change pressure switch.
Change filter.
Tighten connection and repair
leak.
Clean or change valves.
Empty air receiver and
change seal.

PUMP PARTS
1 Screw
2 Lower Cover
3 Casing
4 Bearing
5 Seal
6 Front Cover
7 Screw
8 Flywheel
9 Washer
10 Screw
11 Screw
12 Washer
13 Rear Cover
14 Oil Dipstick
15 Screw
16 Crankshaft
17 Connecting Rod
18 Piston Ring Kit
19 Circlip
20 Gudgeon Pin
21 Piston
22 Complete Piston
23 Cylinder
24 Valve Holder Plate
25 Head
26 Filter Cartridge
27 Intake Filter
28 Screw
29 Conveyor
30 Screw
31 Complete Seal Kit
32 Manifold
33 Automatic Discharge Valve
10ND 15ND
014013054
113149015
113167001
033027000
010053000
113149008
014013021
013160010
014005001
113160011
014013082
014005025
113149009
012036000
014010044
113167003
113149004
213115002
015098000
113115025
113115026
413115026
113169002
413149080
113149050
017024000
317026000
014002041
113150002
014006121
213168001
-
-
014013054
113149015
113167001
033027000
010053000
113149008
014013021
013160010
014005001
113160011
014013082
014005025
113149009
012036000
014010044
113167003
113150004
213167001
015023000
116025006
113164009
413167006
113167002
413167005
113150022
017003000
317001000
014002041
113150002
014006121
213167002
116091024
011158000
No. Description Part No. Part No.
- 13 -
STARTING THE COMPRESSOR
1. Fully open the receiver drain cock, (located between the wheels).
2. Startthe engine, accordingtothe instructionscontained in the engineservice
manual, and allow to run for 10 minutes.
3. After a ten minute period, close the drain cock then ensure both air outlet
sliding valves are pushed fully INWARDS to close the outlet.
Pressure will build up in the receiver and eventually the air governor will
operatesothat theengineruns off load.The pressure registered on thepressure
gauge should be 100psi.
4. Slide the outlet taps outwards to allow air to escape from the outlets, and
slowly turn the pressure regiulator clockwise. Observe the pressure gauge.
When the pressure has dropped by approx. 20psi, the regulator will cut in
again. Close the sliding outlet valves and pressure in the air receiver will once
again increase
5. Finally, stop the engineand set the pressureregulator to zero pressure(turned
fully anticlockwise) and attach the air hose and air tool.
6. Open the sliding valves then set the pressure regulator to full pressure and
check for air leaks at the tool and connectors.
• Ifleaksareapparent, stoptheengine and setthe regulator tozeropressure
(fullyanticlockwise), press the trigger ofthe toolto ensureno air is present
in the airline, then rectify the problem before proceeding.
• If no leaks are evident, set the outlet pressure to the desired value and
proceed to use the air tool in accordance with the manufacturers
instructions.
- 8 -
Initial Start-up
Fig.2

STOPPING THE COMPRESSOR
At the end of the day, stop the compressor in accordance with the instructions in
the engine manual, then open the drain cock.
Close the air outlet by sliding both valves inwards.
Operate the air tool trigger or operating lever etc., to ensure there is no pressure
in the air line, then disconnect airline and tool.
WARNING!
DO NOT under any circumstances attempt to remove the air tool or disconnect
the air hose until you are satisfied that the pressure has been relieved.
Finally, close the drain cock.
Take care not to touch the engine or pump as they remain hot for some time
after use.
When starting subsequently, start the machine as follows:
1. At the beginning of the day, open the drain cock and allow any condensate
to drain completely, then close the cock.
2. To ease starting, ensure there is no pressure in the pump outlet manifold by
opening the Bleed Valve (See Fig.2).
3. Connect the air hose to one of the outlets and the air tool and set the pressure
regulator to zero pressure (turned fully anticlockwise).
4. Start the engine in accordance with the instructions contained in the engine
service manual, then close the bleed valve and allow pressure to build up.
5. When the the regulator/cut-outhas operated, slide the outlet valveoutwards
fullythen adjustthe pressureregulatorso that thedesired pressureis registered
on the gauge.
6. Check for air leaksat thetool andconnectors...as above, before proceeding
- 9 -
PUMP PARTS
- 12 -

MAINTENANCE
DAILY
a. Drain Air Receiver of any condensate
b. Check engine oil level and top up where necessary. Ensure the dipstick
breather hole is not blocked.
c. Check pump oil level
WEEKLY
a. Clean Pump Air Filter
1. PP10ND
Unscrew pump air filter from inlet manifold. Remove cover and check air
filter. Washinwarmsoapywater ifnecessary, rinsethoroughlyand replace
when completely dry. If it is damaged in any way, replace. Clean the
plastic housing thoroughly before reassembly.
2. PP15ND
Turn Pump AirFilter coverand pullaway to reveal paper element. If badly
contaminated, replace. Remove any loose contaminants if any then
replace.
b. Clean the engine cooling fins.
6 MONTHLY
Repairs should only be carried out by a qualified engineer. If problems
occur, contact your Clarke dealer.
- 10 - - 11 -
PARTS LIST
HS17210-ZE0-822
HS98079-56846
PP10ND
PPH10ND PP15ND
PPH15ND
HS17210-ZE1-822
HS17218-ZE0-821 HS17218-ZE1-821
HS98079-56846
1. HS28442-ZH8-003
2. HS28442-ZH8-003
3. HS28462-ZH8-003
1. HS28442-ZH8-003
2. HS28442-ZH8-003
3. HS28462-ZH8-003
`5100610 `5100610
50mm Pressure Gauge 2000175 2000175
Safety Valve Complete 2000180 2000180
Drain Cock 2000220 2000220
V-Belt 2100061 2100063
Wheel 2100289 2100289
Wheel Retaining Clip 2100306 2100306
Soft Rubber Foot 2100313 2100313
Pump Complete. 1390080 (MK101) 1390085 (MK103)
Pulley 2100085 2100084
Engine complete 800047 (GX120QH) 800055 (GX200QH)
Manifold 3-way CBM45469000 CBM45469000
Air Receiver 1999705 1999705
2100177 2100177
Renew pump lubricating oil.
Drain pump by removing the drain
screw (Arrowed in Fig.3).
Replace screw and top up until oil is
level with the mark on the dipstick,
using SAE40 oil available from your
Clarke dealer as follows:
Compressor oil - 1 litre: Part No. 3050810
Compressor oil - 1 litre: Part No. 3050802
In addition to the above, check the engine manual for service
schedule.
Fig.3