Clarke PP9ND Installation and operation manual

1002
©
Air Compressor
Models: PP9ND & CFP9ND
Operating & Maintenance
Instructions

- 19 -
SPECIFICATIONS
CFP9ND PP9ND
Part Number 2090900 2090920
Engine Type HONDA GC135 HONDA GC135
Pump Type MK236-4S MK236-4S
Air Receiver size 2.65litres 50litres
Max. output Pressure 100psi 100psi
Air Displacement 9cfm 9cfm
Outlet connectors 1/4” BSP 1/4” BSP
Dimensions (mm) 520x360x440 1000x430x790
Weight (kg) 21 50
G’teed Sound Power Level** 99dBLWA 99dBLWA
** 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, asit
sees fit, in the interests of safety or improvement in design.
Copyright: Clarke International, All rights reserved. June,2002
- 2 -
WARNING!
DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS
DOING SO WILL INVALIDATE YOUR GUARANTEE

-3 -
INTRODUCTION
Thank you for purchasing this Clarke Air portable compressor.
The unit is powered by a GC135 (3.5HP) 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 & Using your Air Compressor . CFP9ND ........................................................ 8
PP9ND........................................................... 9
Shutting Down the Compressor ................................................................................. 10
Maintenance............................................................................................................... 11
Troubleshooting........................................................................................................... 12
Parts and Service Contacts ....................................................................................... 15
Parts Lists and Diagrams........................................................................................16-18
Specifications.............................................................................................................. 19
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.
- 18 -
PARTS LIST - ENGINE
HS17211-ZL8-000
HS98079-56846
1.
1. HS28400-ZL8-013ZA
2. HS28462-ZL8003
RECEIVER AND ANCILLIARY PARTS
No. Description Part No.
CFP9ND PP9ND
1 Pump MK 238 137005 137005
2 Engine Honda 4HP 7999010 7999010
4 Drain Cock 2000221 2000221
5 Bottom Entry Gauge 2000171 N/A
6 Safety Valve 2000180 20000180
7 Manifold 4-way FN011276000 N/A
8 Rubber Foot FN116011006 N/A
9 Regulator Assy FN347026000 N/A
10 Back Entry Gauge N/A 2000175
11 1/2” Load Genie N/A 2100177
12 15mm Wheel N/A 2100289
13 Wheel Retaining Clip N/A 2100306
14 Rubber Foot N/A 2100313
15 Mini Filter Regulator N/A 5100610
16 Manifold 3-way N/A CMB45469000

- 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.
• Stopthe engine and ensure the pressure is expelled from the air receiverBEFORE 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 safetyvalves.The maximum pressureisfactory set, and clearly
marked on the machine.
• operate in wet or damp conditions. Keep the machine dry at all times. Similarly, a clean
atmospherewillensureefficient 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.
No. Description Part No.
1 Air Filter Assy ....................................................................... FN317013000
2 Head Bolt M6x45................................................................ FN014002021
3 Cylinder Head.................................................................... FN116001001
4 Spacer................................................................................. FN116060015
5 Heat Shield ......................................................................... FN116060016
6 Screw M6x70 ...................................................................... FN014002029
7 Washer 6.5x18 .................................................................... FN014005044
8 Screw M5x15 ...................................................................... FN014013042
9 Elbow................................................................................... FN011015000
10 Gasket ................................................................................. FN116022009
11 Valve plate ......................................................................... FN116022100
12 Gasket ................................................................................. FN116022010
13 Cylinder............................................................................... FN116022001
14 Screw M8x20 ...................................................................... FN014011064
15 O-Ring ................................................................................. FN010114000
16 Piston Ring Set .................................................................... FN216022002
17 Piston ................................................................................... FN116022004
18 Gudgeon Pin ...................................................................... FN116022040
19 Circlip .................................................................................. FN015001000
20 Piston Complete ................................................................ FN416022004
21 Con-Rod ............................................................................. FN116091021
22 Dipstick................................................................................ FN012035000
23 Washer ................................................................................ FN010072000
24 Screw M6x10 ...................................................................... FN014013024
25 End Casing ......................................................................... FN016032014
26 Screw................................................................................... FN014006083
27 Gasket ................................................................................. FN116001025
28 Screw................................................................................... FN014022001
29 Eccentric ............................................................................ FN116060005
30 Key ....................................................................................... FN116060006
31 Crankshaft .......................................................................... FN116060001
32 Bearing................................................................................ FN033058000
33 Seal ...................................................................................... FN010060000
34 Crankcase .......................................................................... FN116060011
35 Casing ................................................................................. FN116060003
36 Screw M5x20 ...................................................................... FN014013046
37 Screw M5x25 ...................................................................... FN014013045
38 Fan ....................................................................................... FN016060002
39 End Casing ......................................................................... FN116060004
40 Shield ................................................................................... FN116060010
41 Gasket Kit............................................................................ FN216GA0001
PUMP PARTS
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- 5 -
z
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 smokingorusing a naked flame nearthe compressor.
•start the engine if there is spilled fuel. Any spillage must be wiped clean and the
compressorallowed 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.)
PUMP PARTS
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PP9ND
Fig.1
- 6 -
PARTS LISTS AND DIAGRAMS
- 15 -
CFP9ND
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]
Spare Parts and Service Contacts

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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
Checkoilandfuellevelsand avisualcheckofcomponents.Refertoengineservicemanual.
C. Pump
• Check oil level on the Dipstick - to level marked.
D. Fueling
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 servicable
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
• Drainoff anycondensate, byopeningthe draincock (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 with model PP9ND
• Attach the air tool/spray gun to the air hose...If using snap couplings, use
a whip end, available from your Clarke dealer.
z
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Large amount of condensation in
air receiver.
Leaks in system
Compressor unit runs
on and off load more
frequently than usual.
Compressor unit runs
‘on load’ when no air is
being used.
Leaks in system.
Compressor’s oil
consumption rising. Too much oil in compressor.
Cylinder worn.
Oil in the air delivered.
Oil level rises although
no oil has been put in.
Piping installation incorrect.
Compressor taking in air which is
too warm.
Condensation at outlet
points.
Drain off condensation Regularly
(Every day before use).
Locate leaks (by means of soapy
water) and repair.
Locate leaks (by means of
soapy water) and repair.
Intake air filter blocked.
Sump over full.
Leaks around crank case.
Working temperature of
compressor too high because of
insufficient cooling.
Cylinder worn.
Check oil level 2 or 3 minutes after
stopping.
Change seal and inspect
packing surfaces. Repair or
replace defective parts.
Increase ventilation to air
compressor.
Replace worn parts or send
compressor pump for an
overhaul.
Reduce oil to correct level.
Replace worn parts or send
compressor pump for an
overhaul.
Change air filter.
Compressor over dimensioned.
Intake air filter blocked.
Condensation in oil pump.
Consult your local dealer.
Obtain better fresh-air supply to
compressor.
Change air filter.

STARTING AND USING THE COMPRESSOR
1. CFP9D
NOTE: For first time operation, disconnect the air hose from the air outlet and
proceed as follows:
1. Start theengine, accordingto theinstructions containedin theengine service
manual, and allow to run for 10 minutes.
2. After atenminuteperiod, stopthe
engine and attach an air hose to
the air outlet and the tool.
3. Screw the pressure regulator fully
anticlockwise, then restart the
engineand allowpresure tobuild
up in the receiver.
Screw the pressure regulator
clockwise until the pressure,
registeredonthePressure Gauge,
is 100psi.
Atthis point, checkthe systemfor
airleaks. Ifany areapparent,stop
the engine and operate the tool
until the air pressure is at zero, or
open the drain cocks before
rectifying.
4. With the engine running, turn the pressure regulator so that your desired
pressure is registered on the gauge, and proceed to use the air tool in
accordance with the manufacturers instructions.
When starting subsequently, start the machine as follows:
1. At the begining of the day, open the drain cock (see Fig.1) and allow any
condensate to drain completely, then close the cock.
2. Connect the air hose to the air outlet and tool, and set the pressure regulator
to zero pressure (turned fully anticlockwise).
3. Start the engine in accordance with the instructions contained in the engine
service manual, and allow pressure to build up.
4. When the pressure in the receiver has built up and air blows off at the bleed
hole, turn the outlet pressure regulator clockwise so that the desired pressure is
registered on the pressure gauge and proceed to use the air tool/spray gun.
5. Check forair leaksat thetool andconnectors...as above,before proceeding.
Fig.2
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NOTE: Air will blow off at the bleed hole
when the pressure reaches 100psi,
which is the MAX. operating pressure.
Unusual noise from
compressor. Bolts loose.
Flywheel loose.
Unit installed on an unsuitable
base.
Bearings, piston rings or cylinder
worn.
Valve broken.
Compressor
becomes too hot.
Check, clean/replace.
Insufficient ventilation.
Oil level too low (check 2 or 3
times after stopping).
Fault in valves (machine not
stopping).
Not fully unloading (PP9ND)
Non-return valve partly blocked.
Clean cooling fins and suction
filter.
Blown head gasket (machine
not stopping).
Dirt on cooling fins or suction
filter.
Unit working at too high a
pressure. Reset to correct working pressure
on Load Genie
Check pressure unloading genie,
adjust if necessary, check
valve(s).
Clean or thaw out non return
valve.
Use a larger capacity
compressor
See that sufficient air is supplied to
flywheel or fan of compressor and
that hot air is properly vented.
Fill with oil – see Page 10.
Tighten bolts.
Tighten flywheel.
Move unit to a more solid base.
Check and replace gasket.
Replace worn parts or change
compressor pump.
Change valve parts.
Compressor being
overworked and running
continuously.
- 13 -

b.
1. Fully open the receiver drain cock, located between the wheels.
2. Start the engine,
according to the
instructionscontained 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 slding valves
are pushed fully INWARDS
to close the outlets.
Pressure will build up in the
receiver and eventually
the air governor will
operateso thatthe 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 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, stopthe engineand set thepressure regulatorto zeropressure (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.
• Ifleaks are apparent,stopthe engineand set theregulator tozeropressure
(fullyanticlockwise), press thetrigger of the tool toensure noair 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.
When starting subsequently, proceed as follows:
1. At the begining of the day, open the drain cock (see Fig.1) and allow any
condensate to drain completely, then close the cock.
Fig.3
- 9 -
PP9ND
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.
- 12 -
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 Load Genie serviced or
replaced
Adjust Load Genie
WARNING: DO NOT ADJUST
LOAD GENIE ABOVE MAXIMUM
WORKING PRESSURE DETAILED.
SYMPTOM
Engine difficult to
start (PP9ND)
PROBABLE
Load Genie leaking
(compressor unit is on load
during start).
Non-return valve blocked,
possibly frozen up.
Compressor unit
constantly ‘on load’
(PP9ND)
Load Genie defective.
Load Genie set at a pressure
higher than the safety
valve’s opening pressure.
Load Genie leaking.
Compressor
constantly ‘on load’
and cannot attain the
working pressure
required.
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 drain plug
leaking.
Change filter.
Tighten connection and
repair leak.
Clean or change valves.
Empty air receiver and
change seals/plugs.
Pressure gauge defective.
Unit too small in relation to
air consumption.
Change pressure gauge.
Use a larger capacity
compressor
Compressor worn. Have compressor overhauled or
replace it.

2. Connect the air hose to the outlet and the air tool and set the pressure
regulator to zero pressure (turned fully anticlockwise).
3. Slide the outlet sliding valves inwards and open the bleed valve.
4. Start the engine in accordance with the instructions contained in the engine
service manual and allow pressure to build up.
5. Close the bleed valve when the Governor/Load Genie has operated and
adjust the pressure regulator so that the desired pressure is registered on the
gauge. Finally, open the sliding valve/s
6. Check forair leaksat the tooland connectors...asabove, beforeproceeding
STOPPING THE COMPRESSOR
At the end of the day, stop the engine in accordance with the instructions in the
engine manual, then open the drain cock.
PP9ND: Close the air outlet by sliding both valves inwards.
Turn the regulator fully anticlockwise.
Operate the air tool trigger or operating lever etc., to ensure there is no pressure
in the air line, then disconnect airline and tool.
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.
- 10 -
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 Filter
1. CFP9D
Unscrew pump air filter from inlet manifold. Remove cover and check air
filter.Washin warm soapywater if necessay,rinse thoroughlyand replace
when completely dry. If it is damaged in any way, replace. Clean the
plastic housing thoroughly before reassembly.
2. PP9ND
Turn Pump 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
- 11 -
In addition to the above, check the engine manual for service
schedule.
Repairs should only be carried out by a qualified engineer. If problems
occur, contact your Clarke dealer.
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
Fig.3