Clarke Champ, 2225220 User guide

AIR COMPRESSOR

MODEL NO: CHAMP

PART NO: 2225215 (230V) & 2225220 (110V)

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL0522 - Rev 6

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 around you, and you can
also look forward to the product giving you long and satisfactory service.

GUARANTEE

This CLARKE 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 to us without prior permission.

This guarantee does not effect your statutory rights.

ENVIRONMENTAL RECYCLING POLICY

Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.

In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

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GENERAL SAFETY WARNINGS

WARNING: WHEN USING ELECTRICAL TOOLS, BASIC SAFETY
PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF
FIRE, ELECTRIC SHOCK AND PERSONAL INJURY

WARNING: READ ALL THESE INSTRUCTIONS BEFORE ATTEMPTING TO
OPERATE THIS PRODUCT AND KEEP THESE INSTRUCTIONS IN A SAFE PLACE.

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
tired or under the influence of medication, drugs or alcohol. A moment of
inattention can result in personal injury.

2. ALWAYS use eye protection when operating compressed air equipment,
and ensure that others in the work area are protected from flying particles
from the front and from the side.

3. ALWAYS protect yourself against electric shock. Never operate the
compressor in wet or damp locations.

4. NEVER over-reach. Keep your proper footing and balance at all times to
enable better control of the compressor in unexpected situations.

5. NEVER attempt any complex repairs yourself. If you have a technical
problem contact your local Clarke dealer.

6. ALWAYS store the compressor out of reach of children.

7. ALWAYS protect your hearing. Ear protection should be worn when
operating this compressor and it’s associated power tools.

8. NEVER direct the air stream at people or animals, as injury may result.
Compressed air can cause soft tissue damage and propel dirt and other
particles at high speed.

9. NEVER insert your fingers or other objects inside the motor housing. Never
operate the compressor without the cover in place.

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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 instructions in this
booklet especially the ON/OFF switch for emergency stopping.

2. ALWAYS maintain the compressor with care and keep it clean for best /
safest performance.

3. NEVER use this compressor if any part is damaged. Have it inspected and
repaired by your dealer.

4. NEVER attempt to modify the air compressor, tank, fittings or attachments in
any way. Doing so will invalidate the guarantee and could result in
personal injury.

5. NEVER abuse the power cable. Never pull on the cable when removing the
plug from the socket, or lift the compressor by the power cable.

6. ONLY use extension leads that are of an appropriate power rating and
suitable for the work environment. Extension leads must have an earth
connection. Inspect the extension lead regularly and replace if damaged.

7. ONLY USE RECOMMENDED PARTS: To avoid the risk of bursting, only hoses
with a rated pressure of 10 bar, or more should be used. Never attempt to
repair damaged hoses.

8. NEVER abuse the compressor by standing on it.

AIRLINE HOSES

1. ALWAYS ensure that equipment or power tools used in conjunction with the
compressor have a safe working pressure exceeding that of the machine.

2. ALWAYS keep the air hose away from any attached power tools and
ensure that the operator is not restricted by the length of the hose.

3. ALWAYS take care when a long air hose is required in the work area as it
presents a trip hazard. Coil the hose away as soon as the job is finished.

4. ALWAYS avoid kinking or trapping the air hose. Always replace faulty hoses
and never attempt a repair if a leak is detected.

5. NEVER abuse hoses or connectors. NEVER carry an air tool by the hose, or
yank it to disconnect from the air supply. Keep hoses away from heat, oil
and sharp edges. Check hoses for leaks or worn condition before use and
ensure that all connections are secure.

6. ALWAYS ensure that the air supply is turned off at the machine outlet and
any air pressure vented from within the compressor and any attached
equipment when disconnecting air hoses or other equipment.

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AIR COMPRESSOR SAFETY INSTRUCTIONS

1. ONLY USE WITHIN THE RECOMMENDED OPERATING TEMPERATURE RANGE:
This compressor should only be used in an ambient temperature of

O

between +5

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 nearest Clarke dealer.

3. BREATHING QUALITY AIR: This compressor should not be used to supply
breathing quality air.

4. SAFETY VALVE: Never remove or attempt to adjust the safety valve. The
maximum pressure is factory set. Keep the safety valve free from paint and
other accumulations.

5. AVOID UNINTENTIONAL STARTING: Do not move the compressor when it is
connected to the mains power supply. When connecting the compressor
to the power supply make sure the red button on top of the control box is in
the OFF (down) position.

C and +40OC (never at or below freezing temperatures).

6. BEFORE EACH USE CHECK THE COMPRESSOR AND HOSE FOR DAMAGED
PARTS: Never use the compressor if it has been damaged in any way. Have
the compressor repaired by a qualified service engineer. Do not use the
compressor if the On/Off switch does not operate correctly.

7. KEEP THE MOTOR AIR VENTS CLEAR: Keep the motor vents clear and free
from dust. Wipe regularly to maintain an adequate supply of clean air.
Avoid using in dusty conditions.

8. OPERATE THE COMPRESSOR AT THE CORRECT VOLTAGE: Make sure that the
mains supply voltage is the same as the voltage shown on the label.

9. ALWAYS adjust the pressure regulator to the recommended setting for the
particular spray gun or air tool being used.

10. When using the compressor for painting:

• Do not work in enclosed areas or near naked flames.

• Ensure that the area in which you are working has good ventilation.

• Protect your nose and mouth with a suitable face mask.

• Always check the safety data sheets for substances being sprayed &
ensure manufacturer’s instructions are followed.

11. DO NOT USE THIS COMPRESSOR TO INFLATE SMALL, LOW-PRESSURE OBJECTS:
Items such as children's toys or footballs can explode if over-inflated.

12. NEVER STOP THE COMPRESSOR BY REMOVING THE PLUG OR SWITCHING OFF
AT THE MAINS SUPPLY: Always use the On/Off switch on the compressor.

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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 removed.

Risk of accidental start-up. The compressor could start
automatically in the event of a power cut and subsequent reset.
Do not carry the compressor while it is connected to the power
source, or when the receiver is filled with compressed air.

Risk of electric shock. The compressor must be disconnected
from the mains supply before removing any covers. Do not use
in a damp environment.

This compressor should always be started or stopped by means
of the start/stop button located on the control box. this reduces
the risk of accidental start-up.

this compressor should never be stopped suddenly by
unplugging from the mains supply. this increases the risk of
accidental start-up. never abuse the power cable

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ELECTRICAL CONNECTIONS

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)

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.

Before switching the product on, make sure that the voltage of your electricity
supply is the same as that indicated on the rating plate. Connecting it to any
other power source may cause damage.

CHAMP/230V

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
because of damage, it must be removed and a replacement fitted, following
the wiring instructions shown below. The old plug must be discarded safely, as
insertion into a power socket could cause an electrical hazard.

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

We strongly recommend that this machine is connected to the mains supply
through a Residual Current Device (RCD).

If you are not sure, consult a qualified electrician. DO NOT try to do any
repairs.

• The BLUE wire must be

connected to the
terminal which is
marked N or coloured
black.

• The BROWN wire must

be connected to the
terminal which is
marked L or coloured
red.

• The YELLOW AND

GREEN wire must be
connected to the terminal which is marked E or or coloured green.

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CHAMP/110V

Plug must be BS60309 approved.

Neutral

Live

Earth

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.

If the plug has to be changed due to damage, a replacement should be
fitted, following the wiring instructions shown below. The old plug must be
disposed of as insertion into a 110v socket could cause an electrical hazard.

WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW = EARTH

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 Blue wire must be
connected to the
terminal which is
marked N or Neutral.

•The Brown wire must
be connected to the
terminal which is
marked L or Live.

•The Yellow wire must
be connected to the
terminal which is
marked E or Earth.

If in any doubt, consult a
qualified electrician. DO
NOT attempt any repairs
yourself.

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OVERVIEW

1 Shut-off valve 8 Oil filler/ dipstick

2 Output pressure regulator 9 Anti-vibration feet

3 On/Off switch 10 Drain valve

4Outlet pressure gauge 11Compressed air reservoir

5 Reservoir 12 Pressure safety valve

6 Handle 13 Pressure control switch

7 Air filter

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PREPARATION FOR USE

WARNING: BEFORE USING THE COMPRESSOR, MAKE SURE THAT YOU
HAVE READ AND UNDERSTOOD THE SAFETY INSTRUCTIONS.

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.

CAUTION: NEVER TAKE THE WEIGHT OF THE COMPRESSOR BY HOLDING
THE PRESSURE CONTROL SWITCH OR OTHER ATTACHED PARTS.

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 on a stable, flat surface.

NOTE: Note: the compressor should not be operated on a steep slope or

floor angle of greater than 15

If the compressor is placed on a shelf or raised off the ground, it should be
secured appropriately to prevent it from falling off during use.

Do not cover the compressor. Always position it with good all-round air
ventilation.

O

.

MOVING THE COMPRESSOR

When moving the compressor;

• Always use the handle/frame.

• Do not lift by (or place a strain on) the airline fittings or hoses.

• Take care to avoid damaging the valves or fittings.

• Always ensure it is switched off and disconnected from the power supply.

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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 which may have accumulated. When clear,
close the valve, finger tight.

IMPORTANT: If the receiver is under pressure, keep your hands well away
from the air being expelled. Remember, compressed air is DANGEROUS.

WARNING: BEFORE CONNECTING ANY AIR TOOL, MAKE SURE YOU HAVE
READ AND FULLY UNDERSTOOD THE MANUFACTURER’S INSTRUCTION
BOOKLET FOR THE AIR TOOL BEING USED. ALSO ENSURE THAT THE AIR
TOOL IS COMPATIBLE WITH THE COMPRESSOR AND HOSE
SPECIFICATIONS.
IF THE PRESSURE RATING OF THE TOOL IS LESS THAN 10 BAR, THE PRESSURE
REGULATOR MUST BE USED TO ADJUST THE OUTPUT PRESSURE.

1. Connect a suitable air hose to the
compressor outlet and the other
end to the equipment to be used.

2. Attach the air hose to the air
outlet using the hose nut as
shown.

3. Ensure that the drain valve is
closed finger tight as above.

4. Ensure the ON/OFF switch is in the
OFF position, i.e. pushed down,
then plug in the machine and switch ON at the mains supply.

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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.

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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
twisting the end of the valve as shown above. Air should be released when
the knurled part is twisted.

• If the valve does not operate as described, or is stuck, it must be replaced
by your Clarke dealer before the compressor is used.

WARNING: NEVER REMOVE OR ATTEMPT TO ADJUST THE SAFETY VALVE.

• Observe that the compressor stops automatically when the maximum
pressure of 10 bar is reached. The pressure is indicated on the reservoir
pressure gauge shown below.

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 increase pressure &
anti-clockwise to decrease it.

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• The pressure setting will be displayed by the outlet pressure gauge shown.

• Use the regulator locking ring to set the pressure.

NORMAL RUNNING

The compressor is fitted with a combined ON/OFF pressure control switch
whose cut-in and cut-out pressures are factory set.

When the reservoir pressure falls below the minimum threshold setting, (about
2-bar lower than the maximum pressure) the compressor will re-start and will
cut out when the maximum reservoir pressure is achieved.

Note: If the machine pumps continuously without intermittently switching on
and off, the compressor is too small for the demand of the application/tool
being used and damage could result. Consult your Clarke dealer.

OVERLOAD CUT OFF SWITCH

Both the 230v and 110v models have a built in overload cut off switch. This will
activate if the current reaches 16amp.

If the overload cut off switch is activated, allow the machine to cool down
before trying to restart.

SHUTTING DOWN AND STORAGE

Press the red ON/OFF switch to shut off the compressor.

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 be desirable to place a container beneath the compressor to catch
any condensate.

Avoid storing the compressor in an environment where the temperature is
likely to drop to or below freezing.

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MAINTENANCE

WARNING: ALWAYS VENT THE AIR RECEIVER BEFORE CARRYING OUT ANY
ADJUSTMENTS, SERVICING OR MAINTENANCE. NEVER UNSCREW A
CONNECTION WHILST THE AIR RECEIVER IS UNDER PRESSURE. ALWAYS
ENSURE THE RECEIVER HAS BEEN VENTED.

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 removed
from the plastic cover and gently
washed in warm soapy water.
Rinse and allow to dry thoroughly
before re-fitting.

• This should be done more
frequently if the compressor
operates in a very dusty area.)

CAUTION: NEVER OPERATE THE COMPRESSOR WITHOUT THE SPONGE
FILTER FITTED, AS FOREIGN MATTER COULD SERIOUSLY DAMAGE THE
INTERNAL COMPONENTS. IF DAMAGED, THE FILTER SHOULD BE
REPLACED.

2. Keep the cooling fins clear of dust if the machine is being used in a dirty
workplace.

6 MONTHLY/500 HOURS

If the oil has become contaminated it should be replaced as follows;

1. Remove the dipstick and unscrew the drain plug from the crankcase cover
and drain the oil into a container.

NOTE: This operation is best performed when the machine is warm so as

to encourage the oil to drain easily.

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2. Replace the drain plug and re-fill
with fresh oil up to the MAX level
on the dipstick using Clarke SAE40
compressor oil.

CAUTION: PROLONGED EXPOSURE TO USED OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED OIL.

RECOMMENDED OILS

Any compressor oil can be used which is suitable for use at room temperatures
from +5OC to + 40OC.

Clarke SAE40 Compressor Oil (1 litre) is available from your Clarke dealer (part
no 3050810). See the Clarke catalogue for other consumables.

ENVIRONMENTAL PROTECTION

One of the most damaging sources of environmental pollution is oil. Do not
throw away used oil with domestic refuse or flush down a sink or drain. Collect
old oil in a leakproof container and take it to your local waste disposal site.

EVERY 2 YEARS

Check the non-return valve shown
and if necessary, replace the gasket
(O-ring).

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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.

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FAULTFINDING

SYMPTOM PROBLEM SOLUTION

Pressure drop in
the
receiver.

Compressor stops
and will not start
again.

Compressor fails to
reach the set
pressure and
overheats easily.

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 dealer.

Bad electrical connections.
Blown fuse.
Overload cut-out switch
has tripped.

Compressor head gasket
failed or valve damaged.

Check connections. Clean
and tighten as necessary.
Renew/replace fuse.
Switch off machine and
wait 5 minutes before
pressing reset button.

Stop the compressor and
contact your dealer.

Compressor does
not start.

Air found leaking
from the pressure
switch valve when
the compressor is
not running.

Pressure switch
valve leaks after
the compressor
has been running
for more than
about a minute

Air pressure cannot
be adjusted at the
regulator

Air reservoir already
pressurised.

Faulty non-return valve. Vent the receiver totally of

Failure of the empty-start
valve in pressure control
switch.

Broken diaphragm inside
the regulator body.

Open drain valve and expel
some air. Compressor should
re-start when the reservoir
pressure trips the pressure
control switch at app. 95 psi.

air. Remove valve end plug,
carefully clean the valve
end seat and gasket, then
re-assemble. See Fig 11.

Replace the pressure
control switch.

Replace regulator.

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Compressor keeps
running after the
maximum pressure
is reached,
causing the safety
valve to activate.

Incorrect operation of the
pressure control switch.

Contact your Clarke dealer

Compressor
making undue
mechanical noise.

Compressor will
not run.

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.

Compressor is damaged
and needs overhaul

Motor winding burnt out. Contact your Clarke dealer

Stop the compressor and
contact your Clarke dealer.

SPECIFICATION

Model 110V 230V

Part No 2225220 2225215

Power supply 110V@50Hz 230V@50Hz

Fuse rating not fitted

Dimensions (L x W x H) 540 x 300 x 388

Weight 21.5 kg

Air receiver capacity 2.4 litres

Duty cycle S1 (continuous)

Max Air pressure 10 Bar/145 psi

Max flow rate 217L/min (7.6 cu.ft/min)

Operating temperature

Sound power level 95 dB LwA

Guaranteed sound power level 96 dB LwA

Please note that the 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.

+5

o

+40oC

13 amps

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PARTS LIST & DIAGRAM - COMPRESSOR

No Description No Description

1 Safety Valve 9 Oil Cap/Dipstick

2 Air Filter 10 Piston Block

3 Piston Head Cover 11 Cover Plate

4 Valve Plate 12 Capacitor

5 After Cooler 13 Compressor Housing

6 Piston Casing 14 Fan

7 Piston 15 Gasket Seals

8 Piston Rings

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PARTS LIST & DIAGRAM - ANCILLARY ITEMS

No Description No Description

1 Compressor Housing 9 Pressure Switch

2Handle Grip 10Power Cable

3 Support Bracket 11 Reservior Pressure Gauge 0-300psi

4 Safety Valve 12 Outlet Pressure Gauge 0-180psi

5 Condensation Drain Tap 13 Pressure Reducer

6 Locknut 14 Shut Off Valve & Air Outlet

7 Delivery Tube 15 Connecting Tube

8Foot 16Check Valve

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

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