Clarke Boxer 2 14/200, 2245315 User guide

200L BELT DRIVEN AIR COMPRESSOR

MODEL NO: BOXER II 14/200

PART NO: 2245315

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0721

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.

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.

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.

2

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

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. DO NOT point a jet of air at persons or animals, and do
not 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 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 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 usage.

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.

3

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

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. DO NOT move the compressor while it is connected
to the power source, or when the tank is filled with
compressed air.

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.

4

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

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
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

• 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.

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.

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

5

BEFORE USE

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

Before connecting your compressor to the power supply, check the following:

• Set the ON/OFF switch to the
OFF position (pushed down).

• Make sure that the compressor
is on level ground.

• Make sure that the supply
voltage matches the voltage
shown on the data label.

CHECK THE OIL LEVEL

1. Remove the dipstick from the oil
reservoir.

2. Ensure the oil level is between the
min and max marks on the
dipstick.

• Only use CLARKE ISO100

(SAE30) compressor oil,
available from your CLARKE
dealer Part No. 3050796.

• Take care not to fill above the

maximum mark.

6

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

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.

MOVING THE AIR COMPRESSOR

• Stop the compressor and disconnect it from the power supply
before you move it.

• Do not lift by (or put strain on) valves or hoses.

• Avoid moving the machine if the tank is fully pressurised.

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. Attach the air hose to the outlet
valves.

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

3. Turn the outlet valve handle to the
on position.

NOTE: The outlet valve is shown

without the air hose fitted for
clarity.

NOTE: To adjust the output pressure

we recommend that a
pressure regulator (not
supplied) be fitted between
the compressor and the tool.

7

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

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.

CHECKING 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 end 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.

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

8

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

REMOVING TOOLS FROM THE AIR HOSE

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

2. Turn the outlet valve handle to the
off position.

3. Operate the tool to depressurise
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 outlet valve to depressurise the reservoir.

• You will hear a hissing sound as the reservoir depressurises.

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

9

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

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.

3. Open the drain valve slowly.

• Condensation will drain from

the reservoir.

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

USING THE RESET BUTTON

This compressor has a thermal
overload device.

If the motor gets too hot, the thermal
overload device cuts the power
which prevents damage to the motor.

If the thermal overload device
operates, let the motor cool down for
5 minutes and push the reset button.

If you start the compressor and the
overload cutout operates again, stop
the compressor and disconnect from the power supply and have your
compressor examined by a qualified service agent.

10

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

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.

CHECKING THE OIL

Ensure the oil level is between the min and max marks on the dipstick. See
“Check 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 and pull
the filter from the compressor.

2. Unclip the front and rear of the
filter and pull out the filter
element.

3. 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.

4. Reassemble the filter and refit it to the compressor using the securing bolt.

11

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

REPLACING THE OIL

After the first 100 hours use, replace
the oil using CLARKE ISO100 (SAE30)
compressor oil. Then 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.

CHECKING THE NON-RETURN VALVE

If the reservoir pressure decreases for no apparent reason, it is possible that the
non-return 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.

12

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

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 pulley.

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

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

• Take care to avoid trapping

your fingers between the pulley
and belt.

6. Replace the cage and secure
before use.

WARNING: NEVER USE THE COMPRESSOR WITH THE GUARD REMOVED.

13

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

TROUBLESHOOTING

CAUTION: DO NOT TRY TO REPAIR OR ADJUSTMENT 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.

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

Compressor is
very noisy and
makes metallic
knocking
sound.

Bad electrical
connections.

Overload cutout switch
has tripped.

Motor windings burnt out. 1. Contact your CLARKE

Compressor head gasket
blown or valve broken.

The reservoir has already
fully pressurised.

Faulty non-return valve. 1. Drain receiver completely

Compressor is damaged
and needs overhaul.

1. Check electrical
connections.

2. Clean and tighten if
necessary.

1. Switch off and wait approx
5 minutes.

2. Press the reset button and
switch on again.

dealer for a replacement
motor.

1. Return the machine to your
nearest CLARKE dealer.

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

of air.

2. Remove the valve end
plug.

3. Carefully clean the valve
seat and the gasket

4. Reassemble.

1. Return the machine to your
nearest CLARKE dealer.

14

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

COMPONENT PARTS

15

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

COMPONENT PARTS LIST

NO DESCRIPTION NO DESCRIPTION

1 CRANKCASE 21 CYLINDER HEAD BOLT

2 CYLINDER BODY 22 GASKETS SET COMPLETE

3 CYLINDER HEAD 23 PISTON RING SET

4 CRANKSHAFT 24 PISTON ASSEMBLY

5 LOWER COVER 25 CHECK VALVE

6 VALVE HOLDER ASSEMBLY 26 TAP BALL VALVE

7 CONROD 27 TAP BALL VALVE

8 INTAKE FILTER ASSEMBLY 28 GAUGE 50 mm

9 AIR COOLER 29 SAFETY VALVE

10 END COVER 30 OUTLET CONNECTOR

11 BEARING HOUSING 31 ON/OFF PRESS SWITCH

12 FLYWHEEL 32 POWER CABLE

13 BEARING 33 MOTOR

14 DIPSTICK 34 BELT GUARD

15 OIL SEAL 35 AIR DELIVERY TUBE

16 O-RING 36 PUMP ASSEMBLY COMPLETE

17 BOLT 37 RUBBER FEET (X4)

18 WASHER 38 RILSAN TUBE

19 COLD START VALVE 39 DRIVE PULLEY

20 SHROUD 40 DRIVE BELT

16

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

SPECIFICATION

MODEL BOXER II 14/200

Part Number 2245315

Motor Power 3 HP

Voltage 230 VAC (50Hz)

Air Displacement 394L/min (14 cfm)

Max Pressure 10 Bar (145 psi)

Receiver Capacity 200 L

Ingress Protection IP20

Fuse Rating 13 A

Duty cycle S3/50%

Oil requirements ISO100 (SAE30) compressor oil

Oil capacity 0.4L

Dimensions (L x W x H) 1540 x 400 x 830 mm

Guaranteed Sound Power Level 97 dB(A)

Weight 97 kg

17

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

DECLARATION OF CONFORMITY

18

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

DECLARATION OF CONFORMITY

19

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