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Air Compressor
Air Compressor
Models: PP9ND & CFP9ND
Operating & Maintenance
Instructions
0208
©
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WARNING!
DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS
DOING SO WILL INVALIDATE YOUR GUARANTEE
SPECIFICATIONS
CFP9ND PP9ND
Part Number 2090900 2090920
Engine Type HONDA GC135 HONDA GC135
Pump Type MK238 MK238
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** 96.5dBL
** 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, as it
sees fit, in the interests of safety or improvement in design.
Copyright: Clarke International, All rights reserved. June,2002
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WA
96.5dBL
WA
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Read these safety instructions before using the equipment.
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.
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.
CONTENTS Page
Specifications ............................................................................................................... 3
Guarantee .................................................................................................................... 4
For your Own Safety .................................................................................................... 5
Important General Notes ............................................................................................ 6
General Layout ............................................................................................................ 7
Preparation for Use ...................................................................................................... 8
Starting & Using your Air Compressor CFP9ND ........................................................ 9
PP9ND ......................................................... 10
Shutting Down the Compressor ............................................................................... 11
Maintenance .............................................................................................................. 12
Troubleshooting ......................................................................................................... 13
Parts and Service Contacts ...................................................................................... 15
Parts Lists and Diagrams ......................................................................................16-18
Declaration of Conformity ........................................................................................ 19
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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.
• 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.
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 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.
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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.
• 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
• ensure there is adequate ventilation when using the compressor.
• position the compressor so that the exhaust is pointed away from people or animals .
NEVER
WARNING:
Exhaust fumes can be fatal
• Do not use the compressor indoors or in an enclosed area. (i.e. in a warehouse, tunnel,
well, hold etc.)
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
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Fig.1
CFP9ND
PP9ND
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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
C. Pump
a visual check of components. Refer to engine service manual.
• Check
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.
oil level on the Dipstick - to level marked.
]
E. Receiver
• Drain off any condensate, by opening the drain cock (see Fig. 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.
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STARTING AND USING THE COMPRESSOR
1. CFP9D
First time startup
NOTE: For first time operation, do not connect the air hose or any tools and proceed
as follows:
1. Start the engine, according to the instructions contained in the engine service
manual, and allow to run for 10 minutes.
2. After a ten minute period, stop the
engine and attach an air hose to
the air outlet and the tool.
3. Screw the pressure regulator fully
anticlockwise, then restart the
engine and allow presure to build
up in the receiver.
Screw the pressure regulator
clockwise until the pressure,
registered on the Pressure Gauge,
is 100psi.
At this point, check the system for air
leaks. If any are apparent, stop the
engine and operate the tool until the
air pressure is at zero, or open the
drain cocks before rectifying.
NOTE: Air will blow off at the bleed hole when the pressure reaches 100psi,
which is the MAX. operating pressure.
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.
Fig.2
When starting subsequently, start the machine as follows:
1. At the begining of the day, open the drain cocks (see Fig.1) and allow any
condensate to drain completely, then close the cocks.
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 for air leaks at the tool and connectors...as above, before proceeding.
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b.
PP9ND
First time startup
1. Fully open the receiver
drain cock, located
between the wheels.
2. Start the engine,
according with the
instructions contained 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 operate so that the 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 regulator clockwise. Observe the pressure gauge.
When the pressure has dropped by approx. 20psi, the air governor/Load Genie
will operate the compressor and will cut in again. Close the sliding outlet valves
and pressure in the air receiver will once again increase
5. Finally, stop the engine and set the pressure regulator to zero pressure (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.
• If leaks are apparent, stop the engine and 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, set the outlet pressure to the desired value and
proceed to use the air tool in accordance with the manufacturers
instructions.
Fig.3
When starting subsequently, proceed as follows:
1. At the begining of the day, open the drain cocks (see Fig.1) and allow any
condensate to drain completely, then close the cocks.
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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, then close the bleed valve and allow pressure to build up.
5.
Adjust the pressure regulator so that the desired pressure is registered on the
gauge. Finally, open the sliding valves
6. Check for air leaks at the tool and connectors as above, before proceeding
STOPPING THE COMPRESSOR (Both models)
At the end of the day, stop the engine in accordance with the instructions in the
engine manual, then open the drain cock.
1. (PP9ND only) Close the air outlet by sliding both valves inwards.
2. Turn the regulator fully anticlockwise.
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.
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.
4. Finally, close the drain cock.
Take care not to touch the engine or pump as they remain hot for some time after
use.
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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/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
Renew pump lubricating oil. and
Make sure the cylider head bolts are
tight (see below)
Drain pump by removing the drain
screw (Arrowed in Fig.3).
Fig.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: Part No.
3050801
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.
Torque values for cylinder head bolts
REBMUNLEDOM
DN9PFC,DN9PP 3.9-8.8
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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.
SYMPTOM
Engine difficult to
start (PP9ND)
Compressor unit
constantly ‘on load’
(PP9ND)
Compressor constantly
‘on load’ and cannot
attain the working
pressure required.
PROBABLE CAUSE
Load Genie leaking
(compressor unit is on load
during start).
Load Genie valve blocked,
possibly frozen up.
Load Genie defective.
Load Genie set at a pressure
higher than the safety
valve’s opening pressure.
Load Genie leaking.
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.
Pressure gauge defective.
Unit too small in relation to
air consumption.
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
Contact Clarke Service
Department
Contact Clarke Service
Department
Clean / Change filter.
Tighten connection and
repair leak.
Contact Clarke Service
Department
Empty air receiver and
change seals/plugs.
Change pressure gauge.
Use a larger capacity
compressor
Compressor worn. Have compressor overhauled or
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replace it.
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Unusual noise from
compressor.
Bolts loose.
Flywheel loose.
Unit installed on an unsuitable
base.
Bearings, piston rings or cylinder
worn.
Valve broken.
Tighten bolts.
Tighten flywheel.
Move unit to a more solid base.
Contact Clarke Service
Department
Contact Clarke Service
Department
Compressor
becomes too hot.
Insufficient ventilation.
Oil level too low (check 2 or 3
times after stopping).
Fault in valves (machine not
stopping).
Blown head gasket (machine
not stopping).
Dirt on cooling fins or suction
filter.
Unit working at too high a
pressure.
Not fully unloading (PP9ND)
Non-return valve partly blocked.
Compressor being
overworked and running
continuously.
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.
Contact Clarke Service
Department
Contact Clarke Service
Department
Clean cooling fins and suction
filter.
Contact Clarke Service
Department
Contact Clarke Service
Department
Clean or that out non return
valve.
Connect to a supplementary
compressor or install a larger
model.
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Compressor unit runs
on and off load more
frequently than usual.
Large amount of condensation in
air receiver.
Leaks in system
Drain off condensation Regularly
(Every day before use).
Locate leaks (by means of soapy
water) and repair.
Compressor unit runs
‘on load’ when no air is
being used.
Compressor’s oil
consumption rising.
Oil in the air delivered.
Oil level rises although
no oil has been put in.
Leaks in system.
Too much oil in compressor.
Leaks around crank case.
Working temperature of
compressor too high because of
insufficient cooling.
Cylinder worn.
Intake air filter blocked.
Sump over full.
Cylinder worn.
Intake air filter blocked.
Condensation in oil pump.
Locate leaks (by means of
soapy water) and repair.
Check oil level 2 or 3 minutes after
stopping.
Contact Clarke Service
Department
Increase ventilation to air
compressor.
Contact Clarke Service
Department
Clean or replace
Reduce oil to correct level.
Contact Clarke Service
Department
Clean / Change air filter.
Compressor over dimensioned.
Condensation at outlet
points.
Piping installation incorrect.
Compressor taking in air which is
too warm.
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Consult your local dealer.
Obtain better fresh-air supply to
compressor.
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PUMP PARTS
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PUMP PARTS
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 ................................................................................
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
FN033058000
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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 1370005 1370005
2 Engine Honda 4HP 7999010 7999010
4 Drain Cock 2000221 2000220
5 Bottom Entry Gauge 2000171 N/A
6 Safety Valve 2000192 20000192
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 2000161
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
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