Clarke WARRIOR 40 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0512
COMPRESSOR
MODEL NO: WARRIOR 40
PART NO: 2322010, 2322015,

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INTRODUCTION
Thank you for purchasing this CLARKE Compressor.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
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 which will be
required 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 to us without prior permission.
This guarantee does not effect your statutory rights.
PARTS AND SERVICING
For Parts & Servicing, 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: [e-mail]

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SAFETY PRECAUTIONS
Before using your compressor it is in your own interest to read and pay attention
to the following safety 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 electrical 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 set the pressure regulator to the recommended setting for the tool.
10. When spraying flammable materials e.g. cellulose paint, ensure that there is
adequate ventilation and keep clear of any possible source of ignition.
11. Before spraying any material always consult paint manufacturers instructions for
safety and usage.
12. Protect yourself. Goggles will protect your eyes from flying particles. Face masks will
protect you against paint spray and/or fumes.
13. Do not exert any strain on electrical cables and ensure that air hoses are not kinked
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 vent 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 had the necessary
training and have read and fully understand these operating instructions.
17. Ensure that any equipment or tool used in conjunction with your compressor, has a
safe working pressure exceeding that of the machine.
18. Exercise caution when transporting the machine to avoid tipping the machine over.
19. Permanently installed systems should be installed by a competent engineer.
20. These Machines produce noise levels in excess of 70dB(A). Persons working in the
vicinity of the machine must be provided with suitable ear protection.

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ELECTRICAL CONNECTIONS
WARRIOR 40, 110V MODEL 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).
WARRIOR 40, 230V MODEL ONLY
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.
If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring instructions
shown below. The old plug must be disposed of safely, as insertion into a mains socket
could cause an electrical hazard.
If the colours of the wires in the power cable of this product do not correspond with the
markings on the terminals of your plug, proceed as follows.
• The wire which is
coloured Blue must be
connected to the
terminal which is marked
Nor coloured Black.
• The wire which is
coloured Brown must be
connected to the
terminal which is marked
Lor coloured Red.
• The wire which is
coloured Yellow and
Green must be
connected to the terminal which is marked E or or coloured Green.
We strongly recommend that this machine is connected to the mains supply via a
Residual Current Device (RCD)
If in any doubt, consult a qualified electrician. DO NOT attempt any repairs yourself
WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.
WARNING! The wires in the power cable of this product are
coloured in accordance with the following code:
Blue = Neutral Brown = Live Yellow and Green = Earth
Plug must be BS1363/A approved.
Always fit
Ensure that the outer sheath of
Neutral
(Blue)
Live
(Brown)
Earth
(Green and
a 13 Amp
the cable is firmly held by the clamp
fuse.
Yellow)

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ASSEMBLY
CAUTION: THE COMPRESSOR IS HEAVY, GET ASSISTANCE WHEN LIFTING
OR MOVING THIS COMPRESSOR TO AVOID PERSONAL INJURY.
FITTING THE WHEELS
Fit the wheels using a suitable
spanner.
FITTING THE SUPPORT FEET
Fit the support feet into place as
shown.
FITTING THE HANDLE
Slide the handle into the position
shown and secure in place using the
fixings provided.

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MOVING THE AIR COMPRESSOR
Before moving the compressor, switch off and disconnect it from the mains
power supply.
• Always use the handle.
• Only move the compressor when it is switched off.
• Do not lift by (or put strain on) fittings, valves or hoses.
• Take care when moving the compressor to avoid damaging the
valves or fittings
BEFORE USE
Before connecting your compressor to the mains supply, check the following:-
• Make sure that the ON/OFF
switch is in the OFF (pressed
down) position.
• Make sure the compressor is on
level ground.
• Check that the mains voltage is
the same as that shown on the
data label on the compressor.
CHECK THE OIL LEVEL
The compressor is supplied without any oil inside.
1. Remove the dipstick from the oil
reservoir.

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2. Add oil until the oil level is between
the min and max marks on the
dipstick.
• Only use SAE40 compressor oil,
available from your Clarke
Dealer.
ATTACHING AIR TOOLS
1. Attach the air hose to the
regulator.
2. Fit the tool to the end of the air
hose.
WARNING: BEFORE CONNECTING ANY AIR TOOLS, MAKE SURE YOU
HAVE READ ANY INSTRUCTIONS SUPPLIED WITH THE TOOL, ALSO ENSURE
THAT THE TOOL IS COMPATIBLE WITH THE COMPRESSOR AND HOSE
SPECIFICATIONS.

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OPERATION
If the compressor has not been used for 24 hours or more, open the drain valve
in the tank to drain any condensate which may have accumulated. See
page 10
1. Insert the plug into the power socket and switch on the power.
2. Lift the On/Off button.
• The compressor will run until the
main tank is fully pressurised. It
will then switch off.
• The compressor will start up
again when the pressure in the
main tank decreases during
use.
3. Make sure the safety valve is
working correctly by pulling on the
ring attached.
• Air should be released when the
ring is pulled and stop when
released.
• If the valve does not operate as
expected, it must be replaced
by qualified service personnel
before the compressor is used.
4. Set the operating pressure you
need using the pressure regulator.
• Clockwise to increase the
pressure
• Anticlockwise to decrease the
pressure
WARNING: DO NOT REMOVE OR ATTEMPT TO ADJUST THE SAFETY VALVE.

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REMOVING TOOLS FROM THE AIR HOSE
1. Push down on the On/Off button
to stop the compressor.
2. Set the pressure regulator to the
lowest setting (fully anticlockwise).
3. Activate the tool (spraygun etc) to
depressurise the air hose
4. The tool can then be
disconnected from the hose,
SHUTTING DOWN THE COMPRESSOR
1. Follow steps 1-3 in “Removing Tools
From The Air Hose” above.
2. Disconnect the compressor from
the mains supply.
• Never leave the compressor
unattended while the tank is
pressurised.
• Always release the pressure
from the tank when not in use or
prior to storage, as described in
the following section.
WARNING: ALWAYS SET THE PRESSURE REGULATOR TO ZERO BEFORE
ATTEMPTING TO REMOVE OR REPLACE A TOOL.

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DRAINING THE TANK
1. Turn the compressor off and
disconnect from the power
supply.
• Put a container beneath the
drain valve to catch any
condensation.
2. Open the drain valve slowly.
• You will hear a hissing sound as
the tank depressurises.
• Any condensation will drain from the tank.
3. Close the drain valve when the tank has fully drained.
RESET BUTTON
This compressor has a thermal
overload device which protects the
motor.
If the motor overheats the thermal
overload device cuts the power thus
preventing damage to the motor.
If the thermal overload device
activates, wait 5 minutes for the motor
to cool and press the reset button.
If you restart the compressor and the
overload cutout activates again, switch off the compressor, Disconnect the
compressor from the mains supply and have your compressor checked by a
qualified service agent.
CAUTION: YOU MUST DRAIN THE TANK AFTER EACH DAYS USE AND
BEFORE YOU STORE YOUR COMPRESSOR.

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MAINTENANCE
CHECKING THE OIL LEVEL (DAILY)
Make sure that there is sufficient oil in the oil reservoir (See page 6) and top-up
if necessary.
• Only use SAE40 compressor oil, available from your Clarke Dealer.
DRAIN THE TANK (DAILY)
When you have finished using the compressor for the day, always open the
drain valve to ensure that any condensate is drained off.
CLEANING THE AIR INTAKE FILTER (MONTHLY)
The air intake filter should be inspected on a monthly basis, and more often in
dusty conditions,
1.
Air Filter Cover
Remove the filter cover from the
compressor as shown.
2. Remove the sponge filter from the
filter cover.
3. Clean the sponge and the filter
cover using a soft brush.
• If necessary, the sponge filter
may be gently washed in warm
soapy water.
• Rinse and allow the filter to dry
thoroughly before refitting.
4. Ensure that the filter and filter cover is replaced in its original position.
• If the filter is damaged, you should obtain a replacement.

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CHECK THE NON RETURN VALVES (EVERY 6 MONTHS)
If the tank pressure decreases for no apparent reason, it is possible that the
non-return valve is leaking. To check,
1. Make sure the tank is not under
pressure and the machine
switched OFF.
2. Examine the non-return valve,
and replace the gasket and valve
if necessary.
SPECIFICATIONS
Warrior 40 Warrior 40 110V
Max.Pressure 10 Bar 10 Bar
Voltag e 230V @ 50HZ 110V @ 50HZ
Air Displacement 9 CFM 9 CFM
Receiver Capacity 24 L 24 L
Fuse Rating 13 A N/A
Dimensions (L x W x H) mm 720 x 306 x 593 720 x 306 x 593
Guaranteed Sound Power Level 97 dB(A) 97 dB(A)
Weight 26.7 kg 26.7 kg
Compressor Oil SAE 30 SAE 30
Please note that the details and specifications contained herein, are correct at
the time of going to print. We reserve the right to change specifications at any
time without prior notice.

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TROUBLESHOOTING
CAUTION: DO NOT ATTEMPT ANY REPAIR OR ADJUSTMENT IF YOU ARE
UNCERTAIN AS TO HOW IT SHOULD BE DONE. IF YOU HAVE ANY QUERIES,
CONTACT YOUR CLARKE DEALER.
PROBLEM PROBABLE CAUSE REMEDY
The compressor
has stopped and
does not start.
Bad electrical connections. 1. Check electrical connections.
2. Clean and tighten as
necessary.
Overload cutout switch has
tripped.
1. Switch off and wait approx 5
minutes.
2. Press the reset button and
switch on again.
Motor windings burnt out. 1. Contact your Clarke dealer for
a replacement motor.
The compressor
does not reach
the set pressure
and overheats
easily.
Compressor head gasket
blown or valve broken.
1. Return the machine to your
nearest service agent.
Compressor does
not start.
The tank has already fully
pressurised.
1. Open drain valve to expel air.
Compressor should start again
when pressure reduces.
Air leaking from
the pressure
switch valve
when the
compressor is not
running.
Faulty non-return valve. 1. Drain receiver completely of
air.
2. Remove the valve end plug,
3. Carefully clean the valve seat
and the gasket
4. Reassemble.
Air pressure from
the regulator will
not adjust.
The diaphragm within the
regulator body is broken.
1. Replace regulator
The compressor is
very noisy and
makes a metallic
knocking sound.
Compressor damaged and
needs overhaul.
1. Return the machine to your
nearest service agent.

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EXPLODED DIAGRAM

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PARTS LIST
No Description Part No
1Complete Casing Cover FN116CN0025
2Mk285-2,5m 230-240/50 FN516NC02605
2Mk285-2,5m 110/50 FN516NC02601
3Oil Dipstick FN012089000
4Crankshaft FN116CN0003
5Casing FN116120006
6Connecting Rod FN116121005
7Piston Ring Set FN213118002
8Complete Piston FN416NC0010
9Cylinder FN116NC0002
10 Valve Holder Plate FN416CN0003
11 Head FN116CN0013
12 Manifold FN016NC0004
13 Filtering Element FN017082001
14 Air Filter Support FN017082002
15 Intake Filter FN317082000
16 Overload Cutout 230v FN008399000
15 Overload Cutout 110v FN008401000
16 Bearing FN033082000
17 Seal Ring FN010132000
18 Rotor FN034104000
19 Condenser 230v FN009200026
19 Condenser 110v FN009200038
20 Wound Casing 230v FN316NC1605
20 Wound Casing 110v FN316NC1601
21 Bearing FN033005000
22 Rear Cover FN116120007
23 Fan FN116120008
24 Circlip FN015083000
25 Housing FN116NC0003
26 Automatic Discharge Valve FN011000183
27 Gaskets Set 230v FN216CN0001
28 Gaskets Set 110v FN216NC0004
29 Base Pioneer Blk
168iq0005v17
FN9416524021
30 Tap Ball Valve 3/8" M FN9047051
31 Plug 1/2" Gas Ei FN9053066
32 Tank 24 3000 Fini Tiger 11 Sht FN9413362053
33 Kit Wheels D150 2r(Fnm) 24l
Ce
FN9420540
34 Rilsan Pipe 4/6 Black FN9270006
35 Saf.valve 1/4" Ce 10bar
Chaoch
FN9049019
36 Nipple 3/8"M-3/8"M
Aftercooler
FN9050511
37 Cord 3x1x1850 Uk
(V230only)
FN9065683
38 Send.pipe Tig.285 Al
168qz0006
FN9043264
39 Handle Tiger 168iq0002 FN9083708
40 Tap Ball Valve R1/4"M R1/
4"M
FN9047077
41 Non Return Valve FN9048063
42 Extens.3/8"1/4"M H50 FN9050510
43 Press.red I1/4 O1/4 G1/8 Std
R
FN9051116
44 Press.sw.4w 1/4" W/vl FN9412071
45 Gauge 50 1/4 P 0-20 10bar FN9414582
46 Gauge 40 1/8 P 0-12 FN9052019
47 Double Screw 1/4"
Gas(0200014)
FN9050373
48 Bicone 10 FN9053156
No Description Part No

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

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POPULAR ACCESSORIES

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NOTES