Clarke PP10ND Installation and operation manual

0307
©
Air Compressor
PP10ND • PPH10ND • PP15ND • PPH15ND
Operating & Maintenance
Instructions
Air Compressor

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WARNING!
DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS
DOING SO WILL INVALIDATE YOUR GUARANTEE
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
** See Declaration of Conformity on back cover
NOTE:
Specifications are correct at the time of going to print.
Clarke International reserves the right to change specifications at any time, as it
sees fit, in the interests of safety or improvement in design.
Copyright: Clarke International, All rights reserved. June,2002

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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.
Specifications ........................................................................................................... 2
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 and Service Contacts ................................................................................... 11
Parts Lists and Diagrams ................................................................................. 12 -14
Troubleshooting ............................................................................................... 15 -17
Declaration of Conformity ..................................................................... Back Cover
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.

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FOR YOUR SAFETY
WARNI NG
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.
• stop the engine and ensure the pressure is 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, or tamper with the safety valves. The maximum pressure is factory set, and clearly
marked on the machine.
• operate in wet or damp conditions. Keep the machine dry at all times. Similarly, a clean
atmosphere will ensure efficient operation. Do not use in dusty 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.

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]
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.
•smoke whilst refuelling and avoid smoking or using a naked flame near the compressor.
•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.)

Fig.1
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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 pump
b) Cooling for compressor pump
c) Engine exhaust gases.
B. Engine
Check oil and fuel levels and a visual check of components. Refer to engine service manual.
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
• Drain off any condensate, by opening the drain cock (see Fig. 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.
]

STARTING THE COMPRESSOR
1. Fully open the receiver drain cock, (located between the wheels).
2. Start the engine, according to the instructions contained in the engine service
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
operate so that the engine runs off load. The pressure registered on the pressure
gauge should be 100psi.
4. Slide the outlet taps outwards to allow air to escape from the outlets, and
slowly turn the pressure regulator clockwise. Observe the pressure gauge.
When the pressure has dropped by approx. 20psi, the Air Governor/Load
Genie will operate and the compressor will cut in again. Close the sliding
outlet valves and pressure in the air receiver will once again increase
5. Finally, stop the engine and set the pressure regulator 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.
• If leaks are apparent, stop the engine and set the regulator to zero pressure
(fully anticlockwise), press the trigger of the tool to ensure no 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.
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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 Air Governor/Load Genie has operated and the compressor has
gone ‘off line’, slide the outlet valve outwards fully then adjust the pressure
regulator so that the desired pressure is registered on the gauge.
6. Check for air leaks at the tool and connectors...as above, before proceeding
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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. Wash in warm soapy water if necessary, rinse thoroughly and replace
when completely dry. If it is damaged in any way, replace. Clean the
plastic housing thoroughly before reassembly.
2. PP15ND
Turn Pump Air Filter cover and pull away 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.
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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 - 5 litre: Part No. 3050802
In addition to the above, check the engine manual for service
schedule.
Fig.3