Clarke BOXER II 14/200 User guide

200L BELT-DRIVEN AIR COMPRESSOR

MODEL NO: BOXER II 14/200

PART NO: 2245315

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL1025 - Rev 3

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.

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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.

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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.
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.

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ELECTRICAL CONNECTIONS

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 marked N or
coloured black.

• The BROWN wire must

be connected to the
terminal marked L or
coloured red.

• The YELLOW AND

GREEN wire must be
connected to the

terminal 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.

(Green and
Yellow)

Plug must be BS1363/A approved.

Earth

Neutral

(Blue)

Ensure that the outer sheath of
the cable is firmly held by the clamp

Always fit
a 13 Amp
fuse.

Live

(Brown)

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BEFORE USE

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

Before installing your compressor, confirm that its output will be sufficient for the
airline equipment to be used. We recommend installing on a firm, level site and the
use of floor mountings with anti-vibration pads. (Do not bolt the machine directly to
the floor).

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. To add oil, unscrew the filler and
using a funnel, fill the compressor
pump with oil.

2. Ensure the oil level is between the
min. and max. marks on the
sight-glass.

• Only use CLARKE -ISO100

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

3050796.

• Take care not to overfill.

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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.

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.

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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.

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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.

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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 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.

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.

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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 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 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.

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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.

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

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.

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.

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

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. Drain receiver completely of

air.

2. Remove the valve end plug.

3. Carefully clean the valve seat
and the gasket

4. Reassemble.

Compressor is damaged and
needs overhaul.

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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 After-cooler

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 Safety Valve

19 Flywheel 49 Pressure Control Switch

20 Flat Washer 50 Pressure Gauge

21 Screw 51 Plug

22 Hex Screw 52 Fixings

23 Cylinder Gasket 53 Non Return Valve

24 Cylinder 54 Discharge Pipe

25 Valve Plate Gasket 55 Hand Valve

26 Valve Plate 56 Hole Plug

27 Copper Gasket 57 Reservoir

28 Valve Reed 58 Drain Valve

29 Head Cover Gasket 59 Motor Pulley

30 Connector Nut 60 Key

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NO DESCRIPTION NO DESCRIPTION

61 V-Belt 65 Safety Guard

62 Flat Washer 66 Plastic Cowling

63 Screw 67 Bracket

64 Screw & Spring Washer 68 Bracket Fixing Parts

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

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

Guaranteed Sound Power Level 97 dB(A)

Weight 97 kg

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DECLARATION OF CONFORMITY - UK

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DECLARATION OF CONFORMITY - CE

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