Clarke REBEL 30 Installation and operation manual

OPERATION & MAINTENANCE
INSTRUCTIONS ©0903
REBEL
REBEL

3
Thank you for purchasing this Rebel Air Compressor which is available in two
configurations - REBEL 30, fitted with a 24 litre air receiver and REBEL60, fitted
with a 50 litre receiver. The REBEL 60 is also available in both 230V and 110V
configurations.
Before attempting to operate the machine, please read this leaflet thoroughly
and carefully follow the 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 the
compressor giving you long and satisfactory service.
GUARANTEE
This 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 the purpose for which it was intended.
Faulty goods should be returned to their place of purchase, no product can be
returned without prior permission. This guarantee does not effect your statutory
rights.
CONTENTS Page
Safety Precautions .......................................................................... 4
Electrical Connections ................................................................... 5
Preparation for Use ......................................................................... 6
Operation ........................................................................................ 6
Shutting Down ................................................................................. 8
Maintenance .................................................................................. 8
Fault Finding .................................................................................. 10
Specifications ................................................................................ 11
Accessories .................................................................................... 11
Parts Lists and Diagrams ........................................................ 12 - 15
Parts and Service ................................................................... 2 & 15

4
SAFETY PRECAUTIONS
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:
1. COMPRESSED AIR IS DANGEROUS, NEVER direct a jet of air at people or animals,
and NEVER discharge compressed air against the skin.
2. DO NOT operate your compressor with any guards removed.
3. Electrical or mechanical repairs should only be carried out by a qualified
engineer. If problems occur, contact your Clarke dealer.
4. Before carrying out any maintenance, ensure the pressure is expelled from
the air receiver, and the machine is disconnected from the mains supply.
5. DO NOT leave pressure in the receiver overnight, or when transporting.
6. DO NOT adjust, or tamper with the safety valves. The maximum pressure is
factory set, and clearly marked on the machine.
7. DO NOT 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.
8. Some of the metal parts can become quite hot during operation. Take care
not to touch these until the machine has cooled down.
9. Always adjust the pressure regulator to the recommended setting for the
particular spray gun or tool being used.
10. When spraying inflammable materials e.g. cellulose paint, ensure that there is
adequate ventilation and keep clear of any possible source of ignition.
11. 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.
12. Before spraying any material always consult paint manufacturers instructions
for safety and usage.
13. Do not exert any strain on electrical cables and ensure that air hoses are not
tangled or wrapped around machinery etc.
14. When disconnecting air hoses or other equipment from your compressor ensure
that the air supply is turned off at the machine outlet and expel all pressurised
air from within the machine and other equipment attached to it.
15. Make sure that children and animals are kept well away from the compressor
and any equipment attached to it.
16. Always ensure that all individuals using the compressor have read and fully
understand the Operating Instructions supplied.
17. Ensure that any equipment or tool used in conjunction with your compressor,
has a safety working pressure exceeding that of the machine.

5
ELECTRICAL CONNECTIONS
REBEL 60, 110V ONLY
Connect the mains lead to a suitable 110V (50Hz) electrical supply through an
approved plug or a suitably fused isolator switch.
If using a portable 110V transformer, make sure it has a rated capacity sufficient
to take the load of the air compressor (see specifications on page 11).
OTHER MODELS
Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through
an approved 13 amp BS 1363 plug, or a suitably fused isolator switch.
WARNING! THIS APPLIANCE MUST BE EARTHED
IMPORTANT: The wires in the mains lead are coloured in accordance with the
following code: Green & Yellow - Earth
Blue - Neutral
Brown - Live
As the colours of the flexible lead of this appliance may not correspond with the
coloured markings identifying terminals in your plug proceed as follows:
Connect GREEN & YELLOW cord to terminal marked with a letter “E” or Earth
symbol “ ” or coloured GREEN or GREEN & YELLOW.
Connect BROWN cord to terminal marked with a letter “L” or coloured RED.
Connect BLUE cord to terminal marked with a letter “N” or coloured BLACK.
If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.
non-rewireable) please note:
1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.
2. Never use the plug without the fuse cover fitted.
3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code).
4. Replacement fuse covers can be obtained from your local dealer or most
electrical stockists.
FUSE RATING
The fuse in the plug must be replaced with one of the same rating (13 amps) and
this replacement must be approved to BS1362.
We recommend that this machine is connected to the mains supply via a Residual
Current Device (RCD)
If in any doubt, DO NOT attempt any connections or repairs yourself. Consult a
qualified electrician, your Clarke dealer, or CLARKE International Service Dep’t on
020 8988 7400 or, e-mail [email protected]

6
PREPARATION FOR USE
NOTE: All numbered items throughout this manual refer to the parts list item number
on Pages 12 to 15.
1. Remove the plastic travel plug from the oil filler hole, on the
top of the crank case, and insert the dipstick (see Fig. 6 - p.9).
2. Check the oil level is at the correct level on the dipstick, as
shown in Fig.1. Where necessary, top up with Clarke SAE40
Compressor Oil (available from your Clarke dealer).
OPERATION (Ref. Fig. 2)
NOTE: if you intend using your compressor for spraying, read also the “Helpful
Hints on Spraying” booklet - supplied with the machine.
1. Check that the mains voltage corresponds with that shown on the data sticker
on the crankcase cover of the machine.
2. Ensure that the ON/OFF knob is in the ‘OFF’ (0) position, i.e. pushed DOWN,
then plug in and switch on at the mains supply.
3. To start the compressor pull UP the ON/OFF knob to the ‘ON’ (I) position
- the motor should start immediately.
Fig.1
Fig. 2
Illustration is of
Rebel 30.
Component
layout for the
Rebel 60 is the
same,
althoughsome
components
differ slightly in
appearance

7
NOTE:
a. Should the motor fail to start immediately, it is
probable that the air receiver is already full of air.
Check the tank pressure gauge (see fig. 2). If you
release air, by opening air outlet tap, the motor will
start automatically once the cut-in pressure is
reached.
b. The compressor is fitted with a pressure relief valve,
shown in fig 2A,to allow ‘no load’ starting. It is normal
for this valve to vent air for a short period when
starting.
4. Before connecting your airline to the compressor allow it to run with the air
outlet tap completely open, for 10 to 15 seconds, to permit a good distribution
of the lubricating oil.
5. Close the outlet tap then connect one end of suitable air hose to the
compressor air outlet, and the other end to the equipment to be used.
Set the outlet pressure by adjusting the Output Pressure Regulator. To do this,
turn the knob clockwise to increase pressure, anti-clockwise to decrease.
The Rebel 60 requires the Regulator Knob to be pulled upwards before it may
be turned. Pushing the knob down again holds the pressure setting. Read
the operating pressure on the outlet pressure gauge.
NOTE:
F or most spraywork do not exceed 50 psi (unless following paint manuf-acturer’s instructions).
For other airline equipment such as air tools, tyre gauges, staple guns, paraffin guns etc., it
may be necessary to set the operating pressure at a higher (or lower) level.
IMPORTANT: Always refer to the accessory manufacturers’ recommendations
for optimum operating pressures for their equipment.
6. With operating pressure set, re-open the air outlet tap.
7. The Pressure Switch, located within the plastic cover beneath the ON/OFF
knob, should not require adjustment. This is an automatic device and has
been pre-set at the factory to stop the motor when pressure in the receiver
reaches its maximum, and to start it again when the pressure in the receiver
falls to the minimum preset value. This operation is completely automatic and
does not affect the spraying process in any way. However, should problems
develop with the cut-in, cut out settings,
please consult your Clarke dealer, or
the Clarke Service Dep’t.
NOTE:
a. If the machine pumps continuously without
cutting out then the compressor is too small
for the application/tool being used, and
damage may result. Consult your Clarke
dealer.
Fig. 3
Fig. 2A

b. The motor is protected by a Thermal Overload so that if the motor overheats for any
reason - the thermal overload will trip, stopping the motor. To restart, allow a period for
the motor to cool down, before pressing the Reset Button, shown in Fig.3.
SHUTTING DOWN THE COMPRESSOR
1. To shut off the compressor, simply press DOWN on the ON/OFF knob (See
Fig. 2) . Always use this knob to shut down the compressor. NEVER USE THE
MAINS SWITCH TO STOP MOTOR.
2. Close the air outlet tap and trigger the equipment (spray gun, air tool etc) to
release air from the air hose before disconnecting the hose from the
machine.
3. Before transporting your compressor or when leaving overnight, expel all air
from the receiver by opening the drain valve (52).
NOTE:
The Rebel 60 incorporates a Regulator/Filter which automatically allows any condensate
to drain off when pressure in the reservoir is completely relieved. Water may also be
drained off when the system is under pressure. The method of operation is shown in Fig 4.
MAINTENANCE
A. DAILY
1. Check the oil level before you start and
top-up if necessary - (useClarke SAE 40
compressor oil available from your local
dealer).
2. Drain any condensate that may have
accumulated in the receiver by
unscrewing the drain plug underneath
the air receiver (fig. 5).
8
Fig. 5
To blow off
condensate when
the system is
pressurised, push the
knob up when it is in
its unlocked position.
Turn the knob, at the
base of the filter
bowl, to the right to
lock it, to the left to
unlock.
In the ‘unlocked’
position, condensate
will automatically
drain when the
pressure in the system
is near zero.
Fig. 4

Fig. 6
9
B. PERIODICALLY
1. After the first 5 hours of running the compressor, check the cylinder head
bolts and motor housing screws and re-tighten if any have worked loose.
2. Every 50 hours (more frequently if used in a dusty environment), clean the air
intake filter, by carefully removing the single screw securing the plastic cover
and withdrawing the sponge element from inside.
Clean the sponge and the inner housing. If necessary, the sponge filter may
be gently washed in warm soapy water, rinsed and allowed to dry thoroughly
before refitting. Ensure that the outer filter cover is then screwed back into its
original position.
If any part of the filter is damaged then you should obtain a replacement.
3. After the first 100 hours use, replace the
oil completely using Clarke SAE 40
compressor oil. Thereafter, replace the
oil completely after every 500 hours
of operation or every 6 months.
To empty the oil from the machine,
remove the drain plug from the
crankcase cover (see fig. 6).
4. Every 500 hours of operation or every
6 months
• clean all the external parts of the
compressor.
(This cleaning makes the cooling
process more efficient and prolongs
the life of the machine).
• Check and clean the inlet and outlet
valves
• Examine the non-return valve and
replace the gasket if necessary (fig.7)
5. In the event of an air leak follow the procedure below:
• Load compressor to maximum pressure
• Unplug the compressor
• With a brush and soapy water wet all ‘screwed’ air connections
• Any leaks will show through the formation of air bubbles.
WARNING
NEVER UNSCREW A CONNECTION WHILST THE AIR RECEIVER IS UNDER PRESSURE.
ALWAYS MAKE CERTAIN THAT THE TANK HAS FIRST BEEN EMPTIED.
Fig. 7
Parts List item No. 59

10
PROBLEM PROBABLE CAUSE REMEDY
The compressor
stops and will not
start again.
Bad connections. Check the electrical
connections.
Clean and tighten as
necessary.
Blown fuse
Overload cutout
switch has tripped.
Renew/Replace fuse
Switch off and wait 5 minutes
before pressing the reset button.
The compressor
does not reach
the set pressure
and overheats
easily.
Compressor head
gasket blown or valve
broken.
Wait for compressor to cool
down, disassemble the head
and replace any broken
components.
Carefully clean all sealing
surfaces before reassembling.
If in doubt contact your
nearest dealer.
NOTE: It is also possible that
you are using more air than
the compressor is capable of
delivering.
Compressor does
not start.
Air receiver charged
(see also item 1)
Open drain cock to expel air.
Compressor should start again
when pressure reduces to
approx 95 psi.
Air leaking from
the pressure switch
valvewhen the
compressor is not
running.
Faulty non-return
valve.
First drain the receiver
completely of air. Remove the
valve end plug, carefully
clean the valve seat and the
gasket and reassemble. See Fig7.
Air pressure from
the regulator will
not adjust.
Replace RegulatorThe diaphragm within
the regulator body is
broken.
The compressor is
very noisy and
makes a metallic
knocking sound.
Return the machine to your
nearest service agent.
Compressor damaged
and needs overhaul.
FAULT FINDING

SPECIFICATIONS
Rotational Speed.................................................. 2850 rpm
Max.Pressure ......................................................... 10 bar
Air Displacement .................................................. 9 cuft/min
Electric Motor ........................................................ 2½ hp (1.8kW)
Nominal Rating ........230 V Models ..................... 9A
110 V Models..................... 25 Amps
Receiver ...................REBEL 30 ............................. 24 LTR
REBEL 60 ............................. 50 LTR
Compressor Oil ..................................................... CLARKE SAE 40
Fuse Rating ...............230 V Models ..................... 13 Amps
110 V Models..................... 25 Amps
Duty Cycle ............................................................ S1
ACCESSORIES
Your Clarke Rebel Air Compressor can be used in conjunction with a range of
optional accessories for inflating tyres, air brushing, stapling, blowing and many
other uses. For details contact your local accessory stockist. A complete kit is
available from your Clarke dealer which is ideal for almost all applications.
Kit Illustrated - KIT1000 - Part Number 3110155
Should you experience any difficulties obtaining accessories, please contact the
Clarke sales department (telephone [phone]) for details of your nearest dealer.
11
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.Always consult the machines’ data plate.
(This machine may be run continuously)

No. Description Qty Part No.
50 Reservoir 1 FN168Z50000V
51 Flat Washer 1 FN014005010
52 Drain valve 1 FN022020000
53 Wheel 2 FN020022000
54 Push On Fastener 2 FN015024000
55 Screw 1 FN014001043
56 Washer 1 FN014005002
57 Anti-vibration Pad 1 FN168E01006
58 Nut 1 FN014003001
59 Valve Assembly 1 FN347043000
60 Valve 1 FN047113001
61 Spring 1 FN047113002
62 Washer 1 FN010041000
63 Tube - FN046001000
64 Valve 1 FN347027000
No. Description Qty Part No.
REBEL 30
65 Adapter 1 FN199110220
66 Pressure Gauge-Res 1 FN330007000
67 Adapter 1 FN011017000
68 Handle 1 FN020121000
69 Output Regulator 1 FN319013000
70 Tap Assy 1 FN322007000
71 Quick Release Conn. 1 FN116011065
72 Pressure Gauge-Line 1 FN330006000
73 Press. Regulator Assy 1 FN321028000
74 Mains lead 1 FN101GA0200
75 Anti-vibration pads 4 FN199575000
76 Adapter 1 FN011248000
77 Pipe 1 FN110GZ0010
78 Plug 2 FN011008000
79 Screw 4 FN014013042
12

No. Description Qty Part No.
50 Reservoir 1 FN170018000V
51 Plug 1 FN011008000
52 Drain valve 1 FN022020000
53 Wheel 2 FN020001000
54 Push On Fastener 2 FN015029000
56 Handle 1 FN020121000
58 Rubber foot 1 FN020093000
59 Valve Assembly 1 FN347043000
60 Valve 1 FN047113001
61 Spring 1 FN047113002
62 Washer 1 FN010041000
64 Valve 1 FN347027000
65 Adapter 1 FN199110140
66 Pressure Gauge-Res 1 FN330007000
67 Adapter 1 FN011017000
68 Pressure Gauge-Line 1 FN330006000
69 Tube - FN046001000
70 Elbow 1 FN011002000
71 Anti-vibration pad 4 FN199575000
72 Pipe 1 FN170GZ0015
73 Adapter 1 FN011248000
74 Screw 4 FN014013042
75 Filter/Regulator Assy 1 FN319042000
76 Press. Regulator Assy 1 FN321028000
77 Mains lead 1 FN101GA0200
78 Tap Assy w/conn 1 FN322008000
79 Quick Fit Coupling 1 FN116011065
13
REBEL 60
No. Description Qty Part No.

COMPRESSOR
14

COMPRESSOR
No. Description Qty Part No.
1 Head Bolt 4 FN014002043
2 Washer 4 FN014005002
3 Cylinder Head 1 FN11691003
4 Filter Unit 1 FN317051000
5 Screw 1 FN014020001
6 Filter Element 1 FN116091018
7 O-Ring 1 FN010085000
8 Screw 3 FN014001044
9 After Cooler 1 FN116091024
10 Head Gasket (Upper) 1 FN116091014
11 Valve Block 2 FN116091012
12 Valve 2 FN116091019
13 Valve Gasket 1 FN116091013
14 Head Gasket (Lower) 1 FN116091015
15 Cylinder Block 1 FN116091008
16 Screw 2 FN014011064
18 Gasket 1 FN116091016
19 Piston Ring set 1 FN213118002
20 Piston 1 FN113118007
21 Gudgoen Pin 1 FN113118030
22 Circlip 2 FN015001000
23 Piston Assy compl. 1 FN413118007
24 Con-Rod 1 FN116091021
25 Overload (230V) 1 FN008015000
25 Overload (110V 1 FN008055000
26 Capacitor (230V) 1 FN009200026
26 Capacitor (110V) 1 FN009200038
27 End Housing Gasket 1 FN116091011
28 Dipstick 1 FN012043000
29 End Housing 1 FN116091002
30 Screw 4 FN014013021
31 Washer 1 FN010072000
32 Screw 1 FN014013024
33 Nut 2 FN014003002
34 Housing 1 FN116091001
35 Circlip 1 FN015005000
36 Shaft Assy. 1 FN116091010
37 Bearing 1 FN033027000
38 Slip Ring 1 FN010029000
39 Rotor 1 FN116091020
40 Stator Assy (230V) 1 FN416091604
40 Stator Assy (110V) 1 FN416091601
41 Bearing 1 FN033005000
42 End Housing 1 FN116011001
43 Screw 2 FN116042020
44 Fan 1 FN116091005
45 Washer 1 FN014005010
46 Screw 4 FN014006121
47 Cover 1 FN010085000
48 Pressure Relief Valve 1 FN011158000
- Gasket Set 1 FN216091001
No. Description Qty Part No.
15
SPARES AND SERVICING
Please contact your local dealer/service agent or the Clarke International on:
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]