Clarke Rebel 35, 2323000 User guide

COMPRESSOR

MODEL NO: REBEL 35

PART NO: 2323000

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0113

INTRODUCTION

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: [email protected]

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

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

2

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 compressor.

18. Exercise caution when transporting the compressor to avoid tipping it over.

19. Permanently installed systems should be installed by a competent engineer.

20. These compressors produce noise levels in excess of 70dB(A). Persons working in the
vicinity of the compressor must be provided with suitable ear protection.

3

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

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.

Yel low)

WARNING! Read these electrical safety instructions thoroughly
before connecting the product to the mains supply.

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.

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

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
N or coloured Black.

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

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

4

ASSEMBLY

CAUTION: THE COMPRESSOR IS HEAVY, GET ASSISTANCE WHEN LIFTING
OR MOVING THIS COMPRESSOR TO AVOID PERSONAL INJURY.

FITTING THE WHEELS

Using the axle and nut, secure the
wheels as shown

Make sure the wheels are secure
before use

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.

5

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CHECK THE OIL LEVEL

NOTE: The compressor is supplied without any oil inside, there will also be

a transit plug inserted into the oil reservoir, which must be
removed and the dipstick supplied inserted in its place.

1. Remove the dipstick from the oil
reservoir.

2. Add oil until the oil level is between
the min and max marks on the

tick.

dips

• Only use SAE40 compressor oil,
available from your Clarke
dealer.

ATTACHING AIR TOOLS

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.

1. Attach the air hose to the
regulator.

2. Fit the tool to the end of the air
hose

.

6

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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 9.

1. Insert the plug into the power sock

2.

Lift the On/Off button.

• The compressor will run until the
tank is fully pressurised. It will
then switch off.

• The compressor will start up
again when the pressure in the
tank decreases during use.

3. Make sure the safety valve is
working correctly by pulling on the

attached.

ring

• 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.

et and switch on the power.

WARNING: DO NOT REMOVE OR ATTEMPT TO ADJUST THE SAFETY VALVE.

Set the operating pressure you

4.
need using the pressure regulator.

• Clockwise to increase the

pressure.

• Anticlockwise to decrease the

pressure.

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REMOVING TOOLS FROM THE AIR HOSE

WARNING: ALWAYS SET THE PRESSURE REGULATOR TO ZERO BEFORE
ATTEMPTING TO REMOVE OR REPLACE A TOOL.

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 (spray gun etc)
to

depressurise the air hose.

4. The tool can then be
disconn

ected 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

• 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.

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

supply.

8

DRAINING THE TANK

CAUTION: YOU MUST DRAIN THE TANK AFTER EACH DAYS USE AND
BEFORE YOU STORE YOUR COMPRESSOR.

1. Turn the compressor off and
disconnect from the power

sup

ply.

• Put a container beneath the

dra

in 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.

• Have your compressor checked by a qualified service agent.

9

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

MAINTENANCE

CHECKING THE OIL LEVEL (DAILY)

Make sure that there is sufficient oil in the oil reservoir (between the min and
max marks on the dipstick, 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. Remove the securing screw from
the air filter cover.

2. Remove the air filter cover from
the compressor

.

3.

Remove the filter element from
the filter cover.

4. Clean the filter element and the
filter cover using a soft

• If necessary, the sponge filter

may be gently washed in warm
soapy water.

• Rinse and allow the filter to dry

thoroughly before refitting.

5. Ensure that the filter element and filter cover ar
position.

• If the filter is damaged, you should obtain a replacement.

6. Replace the securing screw.

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

brush.

e replaced in their original

10

CHECK THE NON RETURN VALVE (EVERY 6 MONTHS)

If the tank pressure decreases for no apparent reason, it is possible that the
non-return valve is leaking. To check the valve:

1. Make sure the tank is not under
pressure and the machine

hed OFF.

switc

2. Examine the non-return valve,
an

d replace the gasket and valve

if necessary.

SPECIFICATIONS

Rebel 35

Max.Pressure 10 Bar

Vo lt ag e 230V @ 50HZ

Air Displacement 10 CFM

Receiver Capacity 24 L

Fuse Rating 13 A

Dimensions (L x W x H) mm 630 x 295 x 653

Guaranteed Sound Power Level 97 dB(A)

Weight 31 kg

Compressor Oil SAE 40

Please note that the details and specifications con
going to print. We reserve the right to change specifications at any time without prior
notice.

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

tained herein, are correct at the time of

11

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

es not start.

do

The compressor

es not reach

do
the set pressure
and overheats
easily.

Compressor does

t start.

no

Air leaking from

e pressure

th
switch valve
when the
compressor is not
running.

Air pressure from

gulator will

the re
not adjust.

The compressor is
ver

y noisy and
makes a metallic
knocking sound.

Bad electrical connections. 1. Check electrical connections.

2. Clean and tighten as
ne

Overload cutout switch has

d.

trippe

Motor windings burnt out. 1. Contact your Clarke dealer for

Compressor head gasket
blown or valve br

The tank has already fully
pressurised.

Faulty non-return valve. 1. Drain receiver completely of

The diaphragm within the
regulator body is broken.

Compressor damaged and

eeds overhaul.

n

oken.

1. Switch off and wait approx 5
minutes.

2. Press the reset button and
swi

a replacemen

1. Wait for the compressor to
cool down,

2. Remove the cylinder head.

3. Replace any broken
co

4. Carefully clean all sealing
sur

If in doubt contact your Clarke
dealer

1. Open drain valve to expel air.
Compressor should start again
when pressure reduces.

air

2. Remove the valve end plug,

3. Carefully clean the valve seat
an

4. Reassemble.

1. Replace regulator

1. Return the machine to your
nearest service agent.

cessary.

tch on again.

t motor.

mponents.

faces before reassembling.

.

.

d the gasket

12

Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

EXPLODED DIAGRAM

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

PARTS LIST

NO DESCRIPTION PAR T N O

1 HEAD FN116091003

2 COOLING FINS FN116091024

3 DISCHARGE VALVE FN011158000

4 FILTER ELEMENT FN116091018

5 FILTER BODY FN116091009

6 VA LVE P L ATE SE T FN116091040

7 CYLINDER FN116002003

8 PISTON RINGS FN213115002

9 PISTON FN113115026

10 PISTON PIN FN113115025

11 CIRCLIP FN015002000

12 COMPLETE PISTON FN413115026

13 OIL DIPSTICK FN012043000

14 FRONT COVER FN016091002

15 SCREW FN014013024

16 CRANKCASE FN116091001

17 CAPACITOR FN116002004

18 CON. ROD FN009200026

19 CIRCLIP FN015005000

20 OVERLOAD CUT-OUT FN008399000

21 CRANKSHAFT FN116091010

22 BEARING FN033027000

23 SEAL FN010029000

24 ROTOR FN034110000

25 STATOR FN416107605

26 BEARING FN033118000

27 BACK COVER FN116011002

28 SCREW M6X150 FN116042020

29 FAN FN116091005

30 SHROUD FN116091007

31 GASKETS KIT FN216AG0001

32 TANK FN9413302053

33 WHEEL FN9042004

34 WHEEL AXLE FN9011056

35 DRAIN VALVE FN9047051

36 RUBBER FOOT FN9038147

37 BASE PLATE FN9083707021

NO DESCRIPTION PART NO

38 VIBRATION DAMPER FN9038450

39 HANDLE FN9038442

40 CONNECTING PIPE FN9043298

41 CONNECTOR FN9416615

42 RILSAN PIPE FN9270006

43 NON RETURN VALVE FN9048007

44 SAFETY RELEASE VALVE

45 PRESSURE SWITCH FN9412071

46 POWER CORD FN9065683

47 CONNECTOR FN9050510

48 GAUGE FN9414582

49 GAUGE FN9052019

50 CONNECTOR FN9050373

51 PRESSURE REGULATOR FN9051116

52 CONNECTION TAP FN9047077

FN9049019

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATION OF CONFORMITY

15

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