Clarke CHAMP Operation & Maintenance Instructions Manual

Text of Clarke CHAMP User Guide:

• Clarke CHAMP, OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC0618 Issue 3 AIR COMPRESSOR MODEL NO: CHAMP PART NO: 2320215 (230V) & 2320220 (110V)

• 2 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] INTRODUCTION Thank you for purchasing this CLARKE Air Compressor. Before attempting to operate the machine, it is essential that you read this manual thoroughly and carefully follow all instructions given. In doing so you will ensure the safety of yourself and that of others aro

• Clarke CHAMP, 3 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] GENERAL SAFETY WARNINGS WORK AREA 1. Keep the work area clean and well lit. Floors should always be kept clear. Cluttered or dark areas invite accidents. 2. Keep children and bystanders away while operating a power tool. Distractions can cause loss of control. 3. The compressor should only be used in areas with adequate ventilation and should not be exposed to heat or used near flammable substances PERSONAL SAFETY 1. ALWAYS stay alert, watch what you are doing and use common sense when operating the compressor. Do not use the compressor while you are

• 4 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] 10. NEVER touch hot surfaces. During operation, the motor, connections, compressor body, cylinder head and tubes may get hot. Do not touch these until the compressor has cooled down. GENERAL MACHINE USE AND CARE 1. Prior to use, all operators should become familiar with the instructio

• Clarke CHAMP, 5 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] AIR COMPRESSOR SAFETY INSTRUCTIONS 1. ONLY USE WITHIN THE RECOMMENDED OPERATING TEMPERATURE RANGE: This compressor should only be used in an ambient temperature of between +5 O C and +40 O C (never at or below freezing temperatures). 2. NEVER USE AN AIR COMPRESSOR WHICH APPEARS DEFECTIVE OR IS OPERATING ABNORMALLY: If the compressor operates unusually or makes strange noises, switch off immediately and purge the air reservoir. Arrange repairs with your ne

• Clarke CHAMP, 6 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] SAFETY SYMBOLS The following safety symbols are shown on the product or it’s packaging. Please read all of the safety and operating instructions carefully before using this product. Read this instruction booklet carefully before positioning, operating or adjusting the compressor. This compressor produces a high sound level during operation. Ear protection should be worn. This compressor contains surfaces which may get hot during operation. Never operate with the motor housing remove

• Clarke CHAMP, 7 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] ELECTRICAL CONNECTIONS Before switching the product on, make sure that the voltage of your electricity supply is the same as that indicated on the rating plate. This product is designed to operate on 230VAC 50Hz. Connecting it to any other power source may cause damage. This product may be fitted with a non-rewireable plug. If it is necessary to change the fuse in the plug, the fuse cover must be refitte

• Clarke CHAMP, 8 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] OVERVIEW 1 Shut-off valve 8 Oil filler/ dipstick 2 Output pressure regulator 9 Anti-vibration feet 3 On/Off switch 10 Drain valve 4 Outlet pressure gauge 11 Compressed air reservoir 5 Reservoir 12 Pressure safety valve 6 Handle 13 Pressure control switch 7 Air filter

• Clarke CHAMP, 9 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] PREPARATION FOR USE UNPACKING Take care when lifting the compressor from the packaging and obtain assistance if necessary to avoid personal injury or damage to the machine. Always use the handle and frame. After removing the compressor from its packaging, check that it has not been damaged in transit. Report any damage immediately to the dealer where the item was purchased. POSITIONING THE COMPRESSOR This compressor should be positioned o

• Clarke CHAMP, 10 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] CONNECTION AND START UP Before connecting your compressor to the mains supply, check the following:- • The supply voltage must be 110V (Champ 110 V - Part No; 2225220) or 230V (Champ 230 V - Part No; 2225215). • The ON/OFF switch is in the OFF (depressed) position. • The pressure regulator should be set at its lowest setting, i.e. turned fully anticlockwise. (- & + arrows are shown on the knob) • If the compressor has not been used recently, open the drain valve shown to drain any condensate whic

• Clarke CHAMP, 11 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] CHECKING THE OIL 1. Remove dipstick as shown and check the level of oil is between the MAX and MIN marks as shown below. If not, top up to the correct level with Clarke SAE40 compressor oil available from your Clarke dealer. 2. After the first 5 working hours, replace the oil as described under MAINTENANCE on page 15.

• Clarke CHAMP, 12 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] OPERATING INSTRUCTIONS STARTING THE COMPRESSOR 1. Pull the ON/OFF switch shown in Fig 5, upwards to start the compressor. The motor should start immediately and run while the reservoir is being pressurised. 2. When starting the compressor for the first time and before connecting it to the airline equipment, leave it running for about 10 minutes to permit a good distribution of lubricating oil. 3. Check the operation of the safety valve under pressure on a daily basis by pulling the ring shown above. Air should be re

• 13 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] WORKING PRESSURE ADJUSTMENT Different air tools which can be powered by the compressor will require different operating pressures to work efficiently. 1. Adjust the air pressure delivered using the pressure regulator. 2. Turn the pressure regulator knob clockwise to increas

• Clarke CHAMP, 14 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] Never stop the compressor by unplugging it from the power supply. It should be turned off as above. After use, set the outlet pressure back to zero. Trigger all equipment (tools, spraygun etc) to release any air pressure from the air hose before disconnecting the hose from the compressor. Before transporting or storing the compressor, release all air pressure from the reservoir by opening the drain valve. • It may b

• Clarke CHAMP, 15 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] MAINTENANCE DAILY / WEEKLY / BEFORE USE 1. Drain any condensate by opening the drain valve fitted to the receiver. As soon as air starts to flow out, close the drain cock. 2. Inspect the compressor for damaged parts or for any loose screws or bolts. 3. Check the oil level is between the MAX & MIN marks on the dipstick & top up if necessary. (Use Clarke SAE40 compressor oil). Ensure the oil does not drop below the minimum level to avoid damage to the machine. PERIODICALLY 1. Check and clean, if necessary, the sponge air inlet filter element shown. The filter may be

• 16 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] 2. Replace the drain plug and re-fill with fresh oil up to the MAX level on the dipstick using Clarke SAE40 compressor oil. RECOMMENDED OILS Any compressor oil can be used which is suitable for use at room temperatures from +5 O C to + 40 O C. Clarke SAE40 Compressor Oil (1 li

• Clarke CHAMP, 17 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] IMPORTANT: The use of parts other than Clarke replacement parts may result in safely hazards, decreased tool performance and will invalidate your warranty. NOTE: Your Clarke compressor has been designed to give long and trouble free service. If, however, having followed the instructions in this booklet carefully, you encounter problems, take the unit to your local Clarke dealer.

• Clarke CHAMP, 18 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] FAULTFINDING SYMPTOM PROBLEM SOLUTION Pressure drop in the receiver. Air leaks at connections. Run the compressor to create maximum pressure. Switch it off and brush a soapy water solution onto all connections. Look carefully for air bubbles being forced out. Tighten any connections where bubbles are seen. If problem persists, contact your Clarke dealer. Compressor stops and will not start again. Bad electrical connections. Blown fuse. Overload cut-out switch has tripped. Check connec

• Clarke CHAMP, 19 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] In the event that any of the above situations arise, requiring the dismantling and overhaul of the compressor, contact your Clarke International Service Department on 020-8988-7400. SPECIFICATION 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

• Clarke CHAMP, 21 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] PARTS LIST - COMPRESSOR No Description Part No No Description Part No 1 END COVER FN116CN0025 24 AIR FILTER HOUSING FN017082002 2 BOLT FN114006024 25 INLET FILTER ASSY FN317082000 3 PLUG/DIPSTICK FN012089000 26 FILTER ELEMENT FN017082001 4CRANKCASE GASKET FN116120016 27 BEARING FN033082000 5 CRANKSHAFT FN116CN0017 28 SEALING RING FN010132000 6 CRANKCASE FN116120006 29 MOTOR ROTOR FN116093005 7 CONNECTING ROD FN116121005 30 OVERLOAD CUTOUT FN0080055000 8 CIRCLIP FN015001000 31 VALVE GASKET FN116CN0051 9 GUDGEON PIN FN116022040 32 BEA

• Clarke CHAMP, 22 Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected] PARTS LIST - ANCILLARY ITEMS No Description Part No No Description Part No 47 FOOT FN20186000 59 T-FITTING FN11177000 48 DRAIN PLUG FN022082000 60 SAFETY VALVE FN047206000 49 BASE PLATE FN104HB0001 61 CONNECTOR FN11017000 50 HANDLE FN116022015 62 PLUG FN111001000 51 DELIVERY TUBE FN104CN0002 63 SHUT-OFF VALVE FN322007000 52 OLIVE FN161535012 64 CONNECTING TUBE FN46001000 53 LOCKNUT FN116HP0011 65 PRESSURE SWITCH FN321028000 54 SPRING FN47159001 66 NON-RETURN VALVE FN347072000 55 O-RING FN10113000 67 AIR RECEIVER FN104HN0001 56 SEAL

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