Clarke CFP10H, 2090903 User guide

AIR COMPRESSOR

MODEL NO: CFP10H

PART NO: 2090903

OPERATING & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0718 ISS 1

INTRODUCTION

Thank you for purchasing this CLARKE Engine Driven 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.

IMPORTANT

WARNING: THIS SYMBOL IS USED THROUGHOUT THE USER GUIDE WHEN
THERE IS A RISK OF PERSONNAL INJURY. MAKE SURE THAT THESE
WARNINGS ARE READ AND UNDERSTOOD AT ALL TIMES.

CAUTION: THIS SYMBOL IS USED THROUGHOUT THE USER GUIDE WHEN
THERE IS A RISK OF DAMAGE TO THE PRODUCT. MAKE SURE THAT THESE
CAUTIONS ARE READ AND UNDERSTOOD AT ALL TIMES.

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.

GENERAL SAFETY PRECAUTIONS

Before using your compressor, read and pay attention to the following safety
guidelines.

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

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2. Compressed air is dangerous. Do not point a jet of air at persons or animals
and do not discharge compressed air against the skin.

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 receiver.

5. DO NOT leave pressure in the air receiver overnight or when transporting.

6. DO NOT adjust or tamper with the safety valve. The maximum pressure is
set at the factory.

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 metal parts can become hot during operation. Do not touch these
until the compressor has cooled down.

9. Always set the pressure regulator to the recommended setting for the air
tool being used.

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

11. Do not use this compressor in explosive atmospheres.

12. Do not operate this compressor in a confined space unless additional
ventilation is provided.

13. Before spraying any material always consult paint manufacturers
instructions for safety and usage.

14. Wear PPE such as goggles to protect your eyes from flying particles. Face
masks will protect you against paint spray and fumes.

15. This compressor will produce noise levels in excess of 70dB(A). Persons
working near the compressor must be equipped with ear protection.

16. Make sure that air hoses are not kinked or wrapped around the compressor
and not subjected to strain.

17. When disconnecting air hoses from your compressor, make sure that the air
supply is turned off at the outlet and vent all pressurised air from within the
air receiver.

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

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

20. Take care when transporting the compressor to prevent tipping over with
resultant spillage of fluids.

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SAFETY SYMBOLS

Refer to instruction manual/booklet.

Hot surface

Wear eye protection

Wear ear protection

This compressor produces a high noise level during
operation.

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BEFORE USE

POSITIONING THE AIR COMPRESSOR IN THE WORKPLACE

1. Always carry the compressor using the handle.

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

3. Before starting, ensure the compressor is standing on a firm level surface
which does not exceed 10

4. Ensure the environment is dry and dust free.

5. Ensure there is adequate ventilation for:

• Air intake to the compressor pump and engine.

• Cooling for the compressor pump and engine.

• Engine exhaust gases.

FILING WITH OIL

The engine and compressor are
supplied without oil inside.

A 1 litre bottle of dual purpose oil is
provided in the box and must be
added before use (approx 0.6 L to
the engine and 0.4 L to the pump).

o

incline, either transversely or longitudinally.

For future use, suitable oils are
available from your Clarke dealer:

1 litre of SAE30 Engine oil - Part No. 3050852

1 litre of SAE30 Air Compressor oil - Part No. 3050796

AIR COMPRESSOR (PUMP)

Remove the compressor dipstick and
add 0.4 L of compressor oil to the
compressor. Check the oil level on
the dipstick

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ENGINE

Remove the engine dipstick and add

0.6 L of engine oil to the engine.

Check that the oil level on the
dipstick is within the hatched area
when the dipstick is removed from
the engine.

Ensure the oil level is visible between
the high (H) and low (L) marks on the
engine dipstick.

ADDING FUEL

Remove the filler cap and fill the tank
with unleaded fuel. (Max capacity

1.8 L)

• Use a funnel to avoid

accidental spillage of fuel.

• If fuel is spilled it must be

cleaned from the unit and
surrounding area before
attempting to start the engine.

• Do not overfill.

STARTING AND USING THE COMPRESSOR

STARTING THE ENGINE FOR THE FIRST TIME

NOTE: For first time operation, do not connect the air hose or any tools

and proceed as follows:

1. Turn fuel valve to the ON position.

2. Set the choke lever to the
(starting) position.

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3. Set the engine switch to the “I”
(ON) position.

4. Hold the starting handle firmly and
pull lightly until you start to feel
resistance, then pull sharply to
start the engine.

NOTE: You may have to do this

more than once.

WARNING: ONCE THE ENGINE HAS STARTED, ALLOW THE STARTING
HANDLE TO RECOIL SLOWLY TO AVOID INJURY/DAMAGE AS IT WHIPS
BACK.

5. When the engine is running steadily, gradually return the choke lever to the
normal running position (to the right).

6. When the engine is running steadily, turn off and attach an air hose to the
compressed air outlet and to the air driven tool.

OIL ALERT SYSTEM

An oil alert system is fitted to prevent engine damage caused by insufficient oil
in the crankcase. Before the oil can fall below a safe limit the oil alert system
will automatically stop the engine although the throttle lever remains in a
running position.

If the engine stops and will not re-start, check the engine oil level before
troubleshooting other areas.

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ATTACHING AIR TOOLS

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

1. Attach the air hose to the air
outlet using an appropriate
connector.

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

• If using snap couplings, use a

whip end, available from your
Clarke dealer.

3. Restart the engine and allow
pressure to build up in the
receiver.

• The gauge will show the available pressure in the receiver.

4. Check the system for air leaks. If any are apparent, stop the engine and
operate the air tool until the air pressure is at zero before rectifying leaks.

NOTE: A self-relieving regulator is fitted which will vent excess air pressure

from the bleed hole when the pressure reaches the maximum.
operating pressure for the compressor.

5. Turn the pressure regulator (clockwise to increase pressure) and proceed
to use your air tool in accordance with its own product instructions.

CHECKING THE SAFETY VALVE

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

1. Check the safety valve to ensure that it works correctly.

2. Pull on the ring attached.

• Air will be released when you pull on the ring and stop when

released.

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3. Do not use the compressor if the
safety valve does not operate in
this way.

• The compressor must be

repaired by a qualified service
agent.

SUBSEQUENT STARTING

1. Connect the air hose to the air outlet and tool and set the pressure
regulator to zero pressure (turned fully anticlockwise).

2. Start the engine and allow pressure to build up.

3. When the pressure in the receiver has built up and air is expelled at the
vent hole, turn the outlet pressure regulator clockwise so that the desired
pressure is shown on the pressure gauge.

4. Check for air leaks at the air tool and connectors before proceeding.

STOPPING THE COMPRESSOR

1. At the end of the day, stop the engine by turning the engine switch to OFF
and closing the fuel valve.

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

3. Open the drain valves slowly.

• Condensation will drain from

the air receiver.

4. Close the drain valve when the air
receiver has fully drained.

5. Turn the air regulator fully
anticlockwise to close off the air
supply.

6. Operate the air tool to discharge
any pressure in the air line before disconnecting the airline and the air tool.

CAUTION: TAKE CARE NOT TO TOUCH THE ENGINE OR COMPRESSOR AS
THEY REMAIN HOT FOR SOME TIME AFTER USE.

CAUTION: DO NOT UNDER ANY CIRCUMSTANCES ATTEMPT TO REMOVE
THE AIR TOOL OR DISCONNECT THE AIR HOSE UNTIL YOU ARE SATISFIED
THAT THE PRESSURE HAS BEEN RELEASED.

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COMPRESSED AIR REQUIREMENTS

WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF A
COMPRESSED AIR SUPPLY.

• If an unusually long air hose is required, (over 8 metres), the line

pressure or the hose inside diameter may need to be increased.

• The air hose must be rated at least 150% of the maximum operating

pressure of the tool.

• If an automatic in-line lubricator/ filter is used it will keep the air tool

in good condition but should be regularly checked & topped up
with oil. Clarke air-line oil should be used and the lubricator adjusted
to approx 2 drops per minute.

• Never exceed the maximum operating pressure for the air tool.

Higher pressures and contaminated air will shorten the life of the tool
due to faster wear and is a possible safety hazard.

MAINTENANCE

DRAIN THE AIR RECEIVER (DAILY/BEFORE USE)

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

CHECK OIL (DAILY)

1. Check the engine oil level is
between the Low and High marks
on the dipstick and top-up if
necessary.

2. Check the compressor oil level in
the same way.

3. Remove each dipstick and wipe it clean, Insert the dipstick into the hole as
far a s it will go, then remove it to check the oil level. Do not overfill. Refit
the dipstick.

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CLEAN THE COMPRESSOR AIR FILTER (MONTHLY)

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

1. Remove the securing wingnut.

2. Lift off the top cover to expose the
filter element.

3. Undo the second wingnut holding
the filter in place and remove the
filter.

4. If necessary, the outer sponge
filter can be carefully cleaned in
warm soapy water.

5. Rinse and let the sponge filter dry
completely before refitting.

6. Clean the main filter element
using a soft brush or a vacuum
cleaner.

• If the main filter element is

damaged it must be replaced.

7. Refit the filters and replace the
cover, securing with the wingnuts
as above.

CHECK THE ENGINE INTAKE FILTER (3 MONTHLY/25 HOURS)

1. Unscrew the engine air intake filter
assembly and prize off the outer
cover by releasing the three small
tabs around the perimeter to
check the filter for cleanliness.

2. Tap the filter against a hard
surface to dislodge loose dirt or
blow through with compressed air.

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3. Do not brush off dirt as it will be
forced into the filter fibres.

4. If necessary, the filter can be
carefully cleaned in warm soapy
water.

5. Rinse and let the filter dry
completely before refitting.

• If the compressor has been

used in a dusty environment,
the filter may need cleaning.

CHANGING THE OIL (6 MONTHLY/50 HOURS)

After the first 100 hours use, replace
the oil using Clarke compressor oil
and Clarke SAE30 engine oil.
Thereafter, replace the oil after every
50 hours of operation or every 6
months.

To empty the oil from the either the
compressor or engine remove the oil
drain plug shown and drain into a
suitable container.

Drain the oil when the engine is warm when it will drain quickly and
completely. A new washer should be used when replacing the drain plug.

CHECKING THE SPARK PLUG (YEARLY/EVERY 100 HOURS OF USE)

CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.

1. Pull the spark plug cap and lead
from the spark plug.

2. Use a spark plug spanner to
remove the spark plug.

3. Check for discolouration and use
abrasive to remove any build up
of carbon.

4. Check the condition of the spark
plug and replace if damaged.

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5. Check the spark plug gap (a) with
a feeler gauge. It should be
between 0.6 and 0.7 mm.

• Adjust if necessary by carefully

bending the electrode.

NOTE: Spark plugs are available

from your Clarke dealer.

6. Re-fit the spark plug taking care
not to cross thread it and tighten
half a turn after the spark plug
seats to compress the washer.

7. Refit the spark plug cap/lead.

EVERY 2 YEARS/250 HOURS

1. Carry out the oil changes.

2. Replace the spark plug and air filter.

3. Request your Clarke dealer to replace fuel lines.

DISPOSAL OF UNWANTED MATERIALS

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

Should any components become completely unserviceable and require
disposal plastic and metal should be disposed of according to local
regulations.

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SPECIFICATIONS

MODEL CFP10H

Engine type Honda GP160

Pump type MK238

Air Receiver size 2.5 litres

Max Output Pressure 100 psi

Air Output volume 9 cfm

Outlet connector 1/4” BSP Male

Dimensions (L x W x H) 510 x 370 x 470 mm

Guaranteed Sound Power Level 97 dB(A)

Weight 21 kg

Engine Oil capacity 0.6 L

Fuel tank capacity 1.8 L

Please note that the details and specifications contained herein, are correct at
the time of going to print. We reserve the right to change specifications at any
time without prior notice.

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TROUBLESHOOTING

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

PROBLEM PROBABLE CAUSE REMEDY

The compressor
fails to start

Engine difficult
to start

Compressor is
constantly ‘on
load’

Compressor has
stopped and
does not start.

Compressor
runs on/off load
more frequently
that usual.

Unusual noise
from
compresso

Compressor
runs ‘on load’
when no air is
being used.

Engine switch is off. Set the engine switch to ‘on’.

No fuel. Add more fuel.

Spark plug damaged or
fouled.

Fuel valve is closed. Open fuel valve

Insufficient starting pull. Pull starter harder.

Regulator blocked/not
working placing
compressor on load.

Defective regulator.
Regulator set to a higher
pressure than the safety
valve’s operating pressure

Faulty or contaminated
carburetor.

Improper or
contaminated fuel.

Dirt in fuel tank. Clean out tank.

Excess condensation in air
receiver.

Leaks in system. Locate any leak using soapy

Unit installed on an
unsuitable base.

r

Compressor damaged
and needs overhaul.

Leaks in the system. Locate leaks by means of soapy

Clean or change the spark plug.

Drain receiver. Clean or replace
regulator.

Service or replace regulator.
Contact Clarke service Dept.

Contact your Clarke service
department.

Check fuel or replace.

Drain off condensation regularly
before use.

water and repair.

Move unit to a more solid base.

Return the machine to your
nearest service agent.

water and repair.

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PROBLEM PROBABLE CAUSE REMEDY

Compressor is
constantly ‘on
load’ and does
not reach the
set pressure.

Inlet filter blocked.

Pressure gauge defective.

Leaks from air receiver
fittings.

Dismantle and clean or return
the machine to your service
agent.

Locate and tighten any loose
connections.

Valves blocked by dirt. Contact your Clarke service

department.

Pressure gauge defective. Replace pressure gauge.

Air leaks from cover or
drain plugs.

Machine too small in

Empty air receiver and change
any leaking seals.

Obtain larger compressor.
relation to air
consumption.

Oil in the air
delivered

Sump is over full.
Cylinder parts badly worn.

Reduce to correct level.

Contact your Clarke service

department.

Compressor’s
oil consumption
rising

Oil level rises in
compressor
pump although

Intake air filter blocked.

Too much oil in compres­sor.
Leaks around crank case.
Working temperature of
compressor too high
because of insufficient
cooling.
Cylinder worn.
Intake air filter blocked.

Condensation in compres­sor pump.

Clean/change air filter.

Check oil level 2 or 3 minutes

after stopping.

Contact Clarke Service

department.

Increase ventilation to air

compressor.

Contact Clarke Service

department.

Clean or replace.

Drain oil completely to remove

condensate and contaminated

oil.

none has been
added.

Condensation
at air outlet

Compressor taking in air
which is too warm.

Obtain better fresh air supply to

compressor.

points

Engine cuts out
and will not re­start.

Lack of oil has caused the
‘low oil cut-out’ to trip and
stop the engine.

Top up engine oil as shown on

page 5.

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PROBLEM PROBABLE CAUSE REMEDY

Compressor
becomes too
hot.

Insufficient ventilation.

Oil level too low (check
after stopping).
Blown head gasket.

Dirt on cooling fins or inlet
filter.
Unit working at too high a
pressure.
Compressor being over­worked and running con­tinuously.

See that sufficient air is supplied

to flywheel or fan of compressor

and that hot air is properly

vented.

Top up oil.

Contact Clarke Service

Department.

Clean cooling fins and inlet filter.

Contact Clarke Service

Department.

Connect to a supplementary

compressor or install a larger

mode.

ANCILLARY COMPONENTS

No Description Part No

1 Pump Assembly MK238 Complete 1370005

2 Honda Engine (type GP160HQX3) 5HP 8000002

3 Drain Cock 2000221

4 Pressure Gauge 2000171

5 Safety Valve 2000191

6 Manifold 4-way FN011276000

7 Rubber Foot FN116011006

8 Regulator FN347026000

9Spark Plug NGK BPR6ES

10 Engine Air Filter Set HS17210ZE1505

11 Recoil Starter Assembly HS28400ZDK003

12 Starter Pull-cord HS28462ZDK003

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PUMP COMPONENTS

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COMPRESSOR COMPONENTS

No Description No Description

1 Air Filter Assembly FN317013000 21 Connecting Rod FN116091021

2 Head Bolt M6 x 45 FN014002021 22 Dipstick FN012035000

3 Cylinder Head FN116001001 23 Washer FN010072000

4 Spacer FN116060015 24 Screw M6 x 10 FN014013024

5 Heat Shield FN116060016 25 End Casing FN016032014

6 Screw M6 x 70 FN014002029 26 Screw FN014006083

7 Washer 6.5 x 18 FN014005044 27 Gasket FN116001025

8 Screw M5 x 18 FN014013042 28 Screw FN014022001

9 Elbow FN011015000 29 Eccentric Lobe FN116060005

10 Gasket FN116022009 30 Key FN116060006

11 Valve Plate FN116022100 31 Crankshaft FN116060001

12 Gasket FN116022010 32 Bearing FN033058000

13 Cylinder FN116022001 33 Seal FN010060000

14 Screw M8 x 20 FN014011064 34 Crankcase FN116060011

15 O-Ring FN010114000 35 End Casing FN116060003

16 Piston Ring Set FN216022002 36 Screw M5 x 20 FN014013046

17 Piston FN116022004 37 Screw M5 x 25 FN014013045

18 Gudgeon Pin FN116022040 38 Fan FN016060002

19 Circlip FN015001000 39 End Casing FN116060004

20 Piston Assembly FN416022004 40 Gasket Kit FN216GA0001

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