Clarke BOXER 18/150V User guide

150L VERTICAL AIR COMPRESSOR

MODEL NO: BOXER 18/150V

PART NO: 2245319

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0625

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 follow all instructions given. This will ensure the safety of yourself and
others and you can look forward to the product giving you long and satisfactory
service.

Before using your compressor it is in your own interest to read and pay attention to
the following safety rules on the following page.

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

By purchasing this product, the customer is taking on the obligation to deal
with its safe disposal in accordance with the Waste Electrical and Electronic
Equipment (WEEE) regulations.

In effect, this means that this product must not be disposed of with general
household waste but 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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SAFETY PRECAUTIONS

1. Compressed air is dangerous. DO NOT point a jet of air at persons or animals or
discharge compressed air against the skin.

2. DO NOT operate your compressor with the guard removed.

3. Repairs must only be carried out by a qualified engineer. If problems occur,
contact your CLARKE dealer.

4. Before carrying out any maintenance make sure that the pressure is released from
the air reservoir and that the compressor is disconnected from the power 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 compressor.

7. DO NOT operate in wet or damp conditions. Keep the compressor dry at all times.
Similarly, clean air will allow the compressor to work efficiently. DO NOT use in
dusty or otherwise dirty locations.

8. Some of the metal parts can become quite hot during operation. DO NOT touch/
remove these until the compressor has cooled down.

9. When spraying flammable materials e.g. cellulose paint, ensure that there is
sufficient airflow and keep clear of any source of ignition.

10. Before spraying any material always consult paint manufacturers instructions for
safety and use.

11. Protect yourself. Goggles will protect your eyes from flying particles. Face masks
will protect you against paint spray and fumes.

12. DO NOT apply strain to electrical cables and make sure that air hoses are not
kinked or wrapped around the compressor.

13. When disconnecting air hoses or other equipment from your compressor, make
sure that the air supply is turned off at the outlet and vent all pressurised air from
within the reservoir and other equipment attached to it.

14. Make sure that children and animals are kept well away from the compressor and
any equipment attached to it.

15. Make sure that all individuals using the compressor have had any necessary
training and have read and fully understand these operating instructions.

16. Make sure that any equipment or tool used in conjunction with your compressor,
has a safe working pressure exceeding that of the compressor.

17. Be careful when transporting the compressor to prevent tipping over.

18. Permanently installed systems must be installed by a competent engineer.

19. These compressors produce noise levels in excess of 70dB(A). Persons working
near the compressor must be supplied with ear protection.

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SAFETY SYMBOLS

Read this instruction booklet carefully before positioning,
operating or adjusting the compressor.

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

Risk of accidental start-up. The compressor could start
automatically in the event of a power cut and subsequent reset.

This compressor contains surfaces which may reach a high
temperature during operation. NEVER operate with the motor
housing removed.

Wear safety goggles when using this compressor

Wear ear protectors when using this compressor

This compressor produces a high sound level during operation.

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INSTALLATION

Before installing your compressor, confirm that its output will be sufficient for the
airline equipment to be used. We recommend the following:

1. A firm, level site and the use of floor mountings with anti-vibration pads. (Do not
bolt the machine directly to the floor).

2. A dust and damp free environment.

3. Adequate ventilation for:

• Air intake to the compressor

• Cooling for the compressor and its electric motor.

4. Sufficient access for servicing. (A minimum clearance of 500mm must be allowed
around the machine).

5. The power cable must be adequate to carry the starting and running load of the
electric motor. This is particularly relevant if the compressor is some distance from
the source of supply.

6. Electrical installations should be completed by a qualified electrician.

ELECTRICAL CONNECTIONS

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

This compressor requires a 32A plug and connection to a MCB Type C
meeting the requirements of BS EN 60309 and having a rated capacity of
greater than 32 Amps.

A standard 13 Amp (BS1363) plug must NOT be used.

WARNING: THIS APPLIANCE MUST BE EARTHED.

IMPORTANT: The wires in this mains lead are coloured in accordance with
the following code:

GREEN AND YELLOW - EARTH (E)

BLUE - NEUTRAL (N)

BROWN - LIVE (L)

As the colours of the flexible cable of this appliance may not correspond with the
coloured markings identifying terminals, proceed as follows:

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• Connect GREEN AND YELLOW coloured cable to terminal marked “E” or Earth
Symbol or coloured Green and Yellow.

• Connect BROWN cable to terminal marked ‘L’ or coloured Red.

• Connect BLUE cable to terminal marked “N’ or coloured Black.

BEFORE USE

CAUTION: TO PREVENT INJURY, GET ASSISTANCE WHEN LIFTING OR
MOVING THIS COMPRESSOR.

Before connecting your compressor to the power supply, check that the supply
voltage matches the voltage shown on the data label.

• Set the ON/OFF switch to the OFF

position (pushed down).

CHECKING THE OIL LEVEL

1. Ensure the oil level is showing at the
correct level through the sight-glass.

2. If not top up after unscrewing the
filler plug.

• Only use ISO100 (SAE30)

compressor oil, available from
your CLARKE dealer Part No.

3050796.

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OPERATION

If the compressor has not been used for more then 24 hours, open the drain valve
(on the bottom of the reservoir) and drain any condensate which has collected. See
page 10.

ATTACHING AIR TOOLS

WARNING: BEFORE CONNECTING AIR TOOLS, MAKE SURE THAT
YOU READ THE INSTRUCTIONS SUPPLIED WITH THE TOOL. ALSO
ENSURE THAT THE TOOL IS SUITABLE FOR USE WITH THE
COMPRESSOR AND HOSE SPECIFICATIONS.

1. Fit the supplied adaptor to the compressor and attach the air hose to the tap.

2. Attach the air tool to the other end of the air hose.

3. Turn the tap handle to the open
position.

NOTE: The tap is shown without the

air hose fitted for clarity.

TURNING THE COMPRESSOR ON

1. Plug the compressor into the power supply.

2. Lift the On/Off button.

• The compressor will operate until the reservoir is fully pressurised. It will

then shut down.

• The compressor will start up again when the pressure in the reservoir

decreases.

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CHECKING THE SAFETY VALVE

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

To make sure that the safety valve works correctly.

1. Unscrew and pull the knurled part of
the safety valve.

• Air will be released when you pull

hard on the valve and stop when
released.

2. If the valve does not operate in this
way, do not use the compressor. The
compressor must be repaired by a
qualified service agent.

3. Once tested, screw the knurled part
back in.

REMOVING TOOLS FROM THE AIR HOSE

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

1. Push down on the On/Off button to
stop the compressor.

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2. Turn the tap handle to the closed
position.

3. Operate the tool to depressurize the
air hose.

4. Disconnect the tool from the hose.

TURNING THE COMPRESSOR OFF

1. Follow steps 1-3 in “Removing Tools From The Air Hose” above.

2. Disconnect the compressor from the power supply.

3. Slowly open the tap to de-pressurize the reservoir.

• You will hear a hissing sound as the reservoir de-pressurizes.

4. Do not leave the compressor unattended if the reservoir is pressurised.

DRAINING THE RESERVOIR

CAUTION: YOU MUST DRAIN THE RESERVOIR AFTER EACH DAYS USE AND
BEFORE YOU PUT YOUR COMPRESSOR INTO STORAGE.

1. Turn the compressor off and disconnect from the power supply.

2. Put a container below the drain valve
to collect the condensate.

• The drain valve is located on the

bottom of the reservoir

3. Open the drain valve slowly.

• Condensation will drain from the

reservoir.

4. Close the drain valve when the
reservoir has fully drained.

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USING THE OVERLOAD RESET BUTTON

The electric motor is fitted with an
automatic overload detector which will
stop the motor if an overload is detected.

If this happens;

1. SWITCH OFF THE MACHINE (Push
the knob down or turn the pressure
switch).

2. Allow the compressor to cool down
for 5-10 minutes.

3. Press the Reset button shown on the right.

4. Switch on the pressure switch (lift the knob or twist switch).

If the overload trips repeatedly it may indicate a fault with the compressor. In this
case you should contact the Clarke service department.

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MAINTENANCE

WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED
FROM THE ELECTRICAL SUPPLY BEFORE CARRYING OUT ANY
MAINTENANCE

DRAIN THE RESERVOIR

After use, always open the drain valve to make sure that any condensate is drained
off.

CHECK OIL

Ensure the oil level is between the min and max marks on the dipstick. See “Checking
the Oil level” on page 6 and top-up if necessary - (use CLARKE ISO100 (SAE30)
compressor oil, available from your local CLARKE dealer).

CLEANING THE AIR FILTER

The air filter must be examined monthly or more often in dusty conditions.

1. Remove the securing bolt with a 7/
32” hex key and pull the filter from

the engine.

2. Remove the filter element and clean
the filter using a soft brush.

• If necessary, the filter can be

carefully cleaned in warm soapy
water.

• Rinse and let the filter dry

completely before refitting.

• If the filter or filter element is damaged you must replace it.

3. Reassemble the filter and refit it to the compressor.

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REPLACING THE OIL

After the first 100 hours use, replace the
oil using CLARKE ISO100 (SAE30)
compressor oil. Thereafter, replace the
oil after every 500 hours of operation or
every 6 months.

To empty the oil from the machine
remove the oil drain plug from the
crankcase.

One of the most damaging sources of
environmental pollution is oil products.
Never throw away used hydraulic oil with domestic refuse or flush it down a sink or
drain. Collect any hydraulic oil in a leak proof container and take it to your local waste
disposal site.

CHECKING THE NON-RETURN VALVE

If the reservoir pressure decreases for no apparent reason it is possible that the non­return valve is leaking. To check this:

1. Make sure that the reservoir is not
under pressure and the compressor is
switched OFF.

2. Examine the non-return valve, and
replace the gasket and valve if
necessary.

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REPLACING THE DRIVE BELT

WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED
FROM THE ELECTRICAL SUPPLY BEFORE REPLACING THE DRIVE
BELT.

1. Rotate the clips on the front of the
safety cage.

2. Remove the front of the cage and
take out the worn or broken drive
belt.

3. Place the new drive belt over the
small wheel.

4. Position part of the drive belt over
the large belt wheel as shown.

5. Rotate the large belt wheel by hand
in a clockwise direction whilst guiding
the belt on to it.

• Take care to avoid trapping your

fingers between the wheel and
belt.

6. Replace the cage and secure before
use.

WARNING: NEVER USE THE COMPRESSOR WITH THE GUARD
REMOVED.

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TROUBLESHOOTING

CAUTION: DO NOT TRY TO REPAIR OR ADJUST IF YOU ARE UNCERTAIN. IF
YOU HAVE ANY QUERIES CONTACT YOUR CLARKE DEALER.

PROBLEM PROBABLE CAUSE REMEDY

The compressor
has stopped and
does not start.

The compressor
does not reach
the set pressure
and overheats
easily.

Compressor does
not start.

Bad electrical connections. 1. Check electrical connections.

2. Clean and tighten if necessary.

Overload cutout switch has
tripped.

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

Compressor head gasket
blown or valve broken.

The reservoir has already
fully pressurised.

1. Switch off and wait approx 5
minutes.

2. Press the reset button and

switch on again.

a replacement motor.

1. Return the machine to your
nearest service agent.

1. Open the drain valve to expel air.
The compressor should start
again when the pressure
reduces.

Air leaking from
the non-return
valve when the
compressor is not
running.

Air pressure from
the regulator will
not adjust.

The compressor
is very noisy and
makes metallic
knocking sound

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

Faulty non-return valve. 1. Fully drain the receiver of air.

2. Remove the valve end plug.

3. Carefully clean the valve seat
and the gasket.

4. Reassemble.

The diaphragm within the
regulator body is broken.

Compressor damaged and
needs overhaul.

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1. Replace the regulator

1. Return the machine to your
nearest CLARKE dealer.

COMPONENT PARTS

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COMPONENT PARTS LIST

NO DESCRIPTION NO DESCRIPTION

1 Screw & Spring Washer 31 Aftercooler

2 Front Cover 32 Screw & Spring Washer

3 Front Cover Gasket 33 Aftercooler Gasket

4 Ball Bearing 34 Screw & Spring Washer

5 Oil Sight-glass 35 Head Cover

6 Breather (M16 x 1.5) 36 Air Filter

8 Crankcase 37 Hex Screw

7 Baseplate Seal 38 Gudgeon Pin

9 Baseplate 39 Compression Ring

10 Screw & Spring Washer 40 Oil Ring

11 Oil Plug (G1/8”) 41 Circlip

12 Crankshaft 42 Piston

13 Ball Bearing 43 Connecting Rod

14 Bearing Seat Gasket 44 Motor Fixing Set

15 Oil Seal 45 Motor

16 Bearing Seat 46 Motor Cable

17 Spring Washer 47 Power Cable

18 Hex Screw 48 Insulating sleeve

19 Flywheel 49 Pressure Control Switch

20 Flat Washer 50 Plug

21 Screw 51 Pressure Gauge

22 Hex Screw 52 Safety Valve

23 Cylinder Gasket 53 Connector

24 Cylinder 54 Ball Valve

25 Valve Plate Gasket 55 Drain Valve

26 Valve Plate 56 Reservoir

27 Copper Gasket 57 Exhaust pipe

28 Valve Reed 58 Check Valve

29 Head Cover Gasket 59 Discharge pipe

30 Connector Nut 60 Motor pulley

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NO DESCRIPTION NO DESCRIPTION

61 Key 66 Safety guard

62 V-belt 67 Plastic Cowling

63 Flat washer 68 Bracket

64 Screw 69 Bracket Fixing Parts

65 Screw & flat washer

SPECIFICATIONS

MODEL Boxer 18/150V

Part Number 2245319

Motor Size 4 HP

Voltage 230 VAC (50Hz)

Total Wattage 3000W

Rated Current 17A

Air Displacement 500L/min (18 cfm)

Max Pressure 10 Bar (145 psi)

Receiver Capacity 150 L

Ingress Protection IP20

Duty cycle S3/50%

Oil Requirements ISO100 (SAE46) compressor oil

Oil Capacity 0.75L

Dimensions (L x W x H) 520 x 580 x 1500 mm

Guaranteed Sound Power Level 97 dB(A)

Weight 89 kg

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DECLARATION OF CONFORMITY - UK

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DECLARATION OF CONFORMITY - CE

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