Clarke XPPV11/50 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0118 - ISS 1
ORIGINAL INSTRUCTIONS
50L ENGINE DRIVEN AIR COMPRESSOR
MODEL NO: XPPV11 & XPP15 RANGE

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INTRODUCTION
Thank you for purchasing this CLARKE compressor which is designed to supply
compressed air to air powered tools for a wide range of applications such as
spraying, sanding, drilling, and cutting.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safe operation
of the compressor.
MODELS COVERED
SPARE PARTS AND DIAGRAMS
Spare parts and diagrams are available on request by contacting our parts
and service department on 020 8988 7400.
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.
XPPV11/50 XPP15/50
XPPVH11/50 XPPH15/50

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SPECIFICATIONS
NOTE: Specifications are correct at the time of going to print. In the
interests of safety or improvement in design, Clarke International
reserves the right to change specifications at any time.
NOISE LEVELS
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.
XPPV11/50 XPPVH11/50 XPP15/50 XPPH15/50
Part Number 2092551 2092556 2092560 2092565
Engine Type Honda 5.5HP Honda 6.5 HP
Displacement CFM 9 9 15 15
Air Receiver size 50 l 50 l 50 l 50 l
Dimensions (mm) L
x W x H
930 x 350 x
800
1000 x 460 x
840
930 x 400 x
800
1000 x 460 x
840
Weight (kg) 32 37 61 67
WARNING: DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS, DOING
SO WILL INVALIDATE YOUR GUARANTEE

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
FOR YOUR SAFETY
GENERAL PRECAUTIONS
ALWAYS
• ensure that all individuals using the compressor have read and fully
understand the Operating Instructions supplied and are suitably trained
• 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. Ear defenders
will prevent hearing damage caused by load noise.
• 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.
DO NOT
• direct a jet of air at people or animals, and NEVER discharge
compressed air against the skin. Compressed air CAN BE dangerous!
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:

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• 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.
FIRE PREVENTION
ALWAYS
• switch the engine OFF when refuelling.
• refuel away from any source of heat.
• refuel in a well ventilated area.
DO NOT
• 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.
EXHAUST GAS PRECAUTIONS
ALWAYS
• Make sure that there is adequate ventilation when using the
compressor.
• Position the compressor so that the exhaust is pointed away from people
or animals.
DO NOT
• use the compressor indoors or in an enclosed area. (i.e. in a warehouse,
tunnel, well, hold etc.)
WARNING: EXHAUST FUMES CAN BE FATAL

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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 re-calibration - consult your Clarke dealer
RESIDUAL RISK
Although this manual contains extensive safety warnings and information on
the safe operation of your compressor, every tool does have certain residual
risks which cannot be completely excluded with warnings or safety devices.
This compressor must therefore always be operated with caution.
OVERVIEW

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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 sightglass - 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 drain 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.
• Attach the air tool/spray gun to the air hose...If using snap couplings, use
a whip end, available from your Clarke dealer.

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STARTING THE COMPRESSOR
INITIAL START-UP
1. Fully open the receiver drain cock, (located between the wheels).
2. To ease starting, ensure there is no pressure in the pump outlet manifold by
opening the Bleed Valve (See Fig.2).
3. Start the engine, according to the instructions contained in the engine
service manual, if this is the first time you use the compressor, allow to run
for 10 minutes.
4. After a ten minute period, close the drain cock and bleed valve then
ensure both air outlet taps are closed (off position).
• 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.
5. 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
6. Finally, stop the engine and set the pressure regulator to zero pressure
(turned fully anticlockwise) and attach the air hose and air tool.
7. Open the sliding valves then set the pressure regulator to full pressure
(100psi) and check for air leaks at the tool and connectors.
• If leaks are apparent, 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,
Open the bleed valve,
start the engine and then
close the bleed valve. Set
the outlet pressure to the
desired value and proceed to use the air tool in accordance with the
manufacturers instructions.
FIG. 2

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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 drain cock.
2. To ease starting, ensure there is no pressure in the pump outlet manifold by
opening the Bleed Valve (See Fig.2 on page 8).
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, before proceeding.
OUTLET PRESSURE ADJUSTMENTS
PORTABLE COMPRESSORS
1. Pressure Adjusting Knob
2. Outlet Taps
3. Pressure Gauge
TO ADJUST OUTLET PRESSURE:
To increase pressure - turn knob (1)
clockwise. To decrease pressure - turn
knob (1) anticlockwise.
Illustrative
purposes
only
FIG. 3

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STOPPING THE COMPRESSOR
1. At the end of the day, stop the compressor in accordance with the
instructions in the engine manual, then open the drain cock.
2. Close the air outlet by sliding both valves inwards.
3. Operate the air tool trigger or operating lever etc., to ensure there is no
pressure in the air line, then disconnect airline and tool.
4. Finally, close the drain cock.
5. Take care not to touch the engine or pump as they remain hot for some
time after use.
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.

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MAINTENANCE
DAILY
1. Drain Air Receiver of any condensate
2. Check engine oil level and top up where necessary. Ensure the dipstick
breather hole is not blocked.
3. Check pump oil level
WEEKLY
1. Clean Pump Air Filter
• Unbolt the Pump Air Filter cover and pull away to reveal foam element.
If badly contaminated, replace. Remove any loose contaminants if any
then replace.
2. Clean the engine cooling fins.
6 MONTHLY
1. Renew pump lubricating oil.
2. Drain pump by removing the drain
plug.
3. Replace screw and top up until oil is
level with the mark on the dipstick,
using SAE30 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.
Repairs should only be carried out by a qualified engineer. If problems occur,
contact your Clarke dealer.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
TROUBLESHOOTING CHART
IMPORTANT!
1. Any remedial work that may be required must be carried out by a qualified
electrician/engineer.
2. Empty Air Receiver of Air before dismantling any part of the compressor
unit’s pressure system.
3. If your compressor develops a fault do not use until the fault has been
rectified.
SYMPTOM PROBABLE CAUSE REMEDY
Engine
difficult to
start
Load Genie leaking
(compressor unit is on load
during start).
Stop engine and empty air
receiver. Clean or replace
Load Genie
Load Genie valve blocked,
possibly frozen up.
Thaw Load Genie out (Unit
must be installed in frost-
free place).
Compressor
unit
constantly ‘on
load’
Load Genie defective Have Load Genie serviced
or replaced
Load Genie set at a pressure
higher than the safety valve’s
opening pressure
Contact Clarke Service
Department
Load Genie leaking. Contact Clarke Service
Department

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Compressor
constantly ‘on
load’ and
cannot attain
the working
pressure
required.
Suction filter blocked. Clean / Change filter.
Leak between compressor
block and air receiver leaks in
or near air receiver.
Tighten connection and
repair leak.
Valves blocked by dirt, paint,
dust or choked up.
Contact Clarke Service
Department
Inspection cover or drain plug
leaking.
Empty air receiver and
change seals/plugs.
Pressure gauge defective Change pressure gauge.
Unit too small in relation to air
consumption.
Use a larger capacity
compressor
Compressor worn. Have compressor
overhauled or replace it.
Unusual noise
from
compressor.
Bolts loose. Tighten bolts
Flywheel loose. Tighten flywheel
Unit installed on an unsuitable
base.
Move unit to a more solid
base
Bearings, piston rings or
cylinder worn.
Contact Clarke Service
Department
Valve broken Contact Clarke Service
Department
SYMPTOM PROBABLE CAUSE REMEDY

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
Compressor
becomes too
hot.
Insufficient ventilation. See that sufficient air is
supplied to flywheel or fan
of compressor and that
hot air is properly vented.
Oil level too low (check 2 or
3 minutes after stopping.
Fill with oil
Fault in valves (machine not
stopping).
Contact Clarke Service
Department
Blown head gasket (machine
not stopping).
Contact Clarke Service
Department
Dirt on cooling fins or suction
filter.
Clean cooling fins and
suction filter.
Unit working at too high a
pressure.
Contact Clarke Service
Department
Not fully unloading Contact Clarke Service
Department
Load genie partly blocked. Contact Clarke Service
Department
Compressor
unit runs on
and off load
more
frequently
than usual.
Large amount of
condensation in air receiver.
Drain off condensation
Regularly (Every day
before use).
Leaks in system Locate leaks (by means of
soapy water) and repair.
Compressor
unit runs ‘on
load’ when
no air is being
used.
Leaks in system Locate leaks (by means of
soapy water) and repair.
SYMPTOM PROBABLE CAUSE REMEDY

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
Compressor’s
oil
consumption
rising.
Too much oil in compressor. Check oil level 2 or
3 minutes after stopping.
Leaks around crank case Contact Clarke Service
Department
Working temperature of
compressor too high because
of insufficient cooling.
Increase ventilation to air
compressor.
Cylinder worn. Contact Clarke Service
Department
Intake air filter blocked Clean or replace
Oil in the air
delivered.
Sump over full Reduce oil to correct level.
Cylinder worn Contact Clarke Service
Department
Intake air filter blocked Clean / Change air filter.
Oil level rises
although no
oil has been
put in.
Condensation in oil pump. Compressor over
dimensioned.
Condensation
at outlet
points.
Piping installation incorrect. Consult your local dealer
Compressor taking in air
which is too warm.
Obtain better fresh-air
supply to compressor.
SYMPTOM PROBABLE CAUSE REMEDY