Clarke Pioneer 100, 2320035 User guide

PIONEER 100

PIONEER 100

AIR COMPRESSOR

AIR COMPRESSOR

OPERATING & MAINTENANCE

INSTRUCTIONS

0104

SPECIFICATIONS

Rotational Speed...................................................2850 rpm

Max. Pressure ......................................................... 8 bar (116psi)

Air Displacement ...................................................100Ltrs/min

PARTS DIAGRAM

RECEIVER ASSY

Electric Motor ......................................................... 0.65HP (0.48HP)

Receiver ................................................................. 10 Ltr

Compressor Oil ......................................................CLARKE SAE 40

Fuse Rating 230V ..................................................13amps

110V ..................................................16A

Gross Weight .......................................................... 25.5kgs

Part Number 230V ................................................. 2320033

110V ..................................................2320035

Duty Cycle .............................................................S1* at 7bar

*The compressor may be run continuously at an output pressure of 7bar

Please note that the details and specifications contained herein, are correct at the time of going to

print. However, CLARKE International reserve the right to change specifications at any time without

prior notice. Always consult the machine’s data plate

2

15

SPARE PARTS

No. Description Qty Part No

50 Tank ....................................................................... 1 ....... FN164A51000V

51 Wheel .................................................................... 2 ....... FN020006000

52 Circlip .................................................................... 2 ....... FN015018000

53 Drain Cock ........................................................... 1 ....... FN022020000

54 Foot........................................................................ 2 ....... FN116011006

55 Plug ........................................................................ 2 ....... FN011008000

56 Vibration Damper................................................ 4 ....... FN199575000

57 Handle................................................................... 2 ....... FN116022015

58 Non Return Valve................................................. 1 ....... FN347043000

59 Gasket ................................................................... 1 ....... FN010041000

60 Spring .................................................................... 1 ....... FN047113002

61 Seal ........................................................................ 1 ....... FN047129001

62 Elbow ..................................................................... 1 ....... FN011055000

63 Rilsan Tube ............................................................ 1 ....... FN046001000

64 Delivery Tube........................................................ 1 ....... FN101GE0011

65 Elbow ..................................................................... 1 ....... FN011015000

66 Nipple .................................................................... 1 ....... FN199110140

67 Power Cord With Plug 240V ............................... 1 ....... FN101GA0200

67 Power Cord 110V................................................. 1 ....... FN165E03200

68 Pressure Switch ..................................................... 1 ....... FN321028000

69 Nipple .................................................................... 1 ....... FN011017000

70 Pressure Reducer ................................................. 1 ....... FN319100000

71 Line Cock.............................................................. 1 ....... FNA04093100

72 Slotted Nut ............................................................ 1 ....... FN116011065

73 Pressure Gauge ................................................... 1 ....... FN330006000

74 Pressure Gauge ................................................... 1 ....... FN330004000

75 Relief Valve.......................................................... 1 ....... FN047205000

Thank you for purchasing this Pioneer Air Compressor which is fitted with a 10litre
air receiver.

Before attempting to operate the machine, please read this leaflet thoroughly
and carefully follow the instructions given. In doing so you will ensure the safety
of yourself and that of others around you, and you can also look forward to the
compressor 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 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 without prior permission.

This guarantee does not effect your statutory rights.

CONTENTS Page

Specifications .................................................................................. 2

Safety Precautions .......................................................................... 4

Electrical Connections ................................................................... 5

Assembly .......................................................................................... 6

Preparation for Use ......................................................................... 6

Operation ........................................................................................ 7

Shutting Down ................................................................................. 8

Maintenance .................................................................................. 9

Accessories .................................................................................... 11

Parts & service Contacts .............................................................. 10

Parts List and Diagrams .........................................................11 - 15

14

3

SAFETY PRECAUTIONS

PARTS DIAGRAM

WARNING!

Compressed air can be dangerous.

Follow these safety instructions carefully.

• NEVER direct a jet of compressed air at people or animals, or spray

paint towards people or animals.
ALWAYS use appropriate protective equipment, such as Clarke safety-

compressed air tools.

• Air compressors work at high pressure. ALWAYS inspect equipment and hoses

before use, checking for any damage or leaks. Have any damage properly
repaired before using the machine again.

• DO NOT operate the compressor with any guards removed.

• DO NOT adjust or tamper with the safety valve in any way. The maximum

working pressure is clearly marked on the compressor.

• The compressor will become hot during operation. DO NOT touch the

• ALWAYS release any pressure from the air hose (by operating the tool briefly)

before disconnecting any hoses or tools.

•

ALWAYS ensure the pressure is expelled from the air receiver, and the machine

is disconnected from the mains supply, BEFORE carrying out any maintenance,

• DO NOT leave pressure in the receiver overnight, or when transporting.

• DO NOT adjust, or tamper with the safety valves. The maximum pressure is

factory set, and clearly marked on the machine.

• ENSURE that any equipment or tool used in conjunction with your compressor,

has a safety working pressure exceeding that of the machine.

• ALWAYS consult paint manufacturers instructions, for safety and usage.before

spraying any material

• ALWAYS ensure that all individuals using the compressor have read and fully

understand the Operating Instructions supplied.

COMPRESSOR ASSY.

When paint spraying:

• ALWAYS wear a suitably approved breathing mask when paint spraying,

to protect against inhalation of paint spray or fumes. An air feed mask
may be required when spraying some types of paint. If in doubt, check the
paint manufacturers instructions.

• Make sure there is adequate ventilation. DO NOT spray in confined or enclosed

areas.

• Many paints are flammable. DO NOT smoke while spraying or preparing paints,

or spray near a naked flame or heat source.

- 4 -

13

SPARE PARTS

ELECTRICAL CONNECTIONS

No. Description Qty Part No

1 Screw.......................................................................4...........FN014002026

2 Head ....................................................................... 1 ...........FN116034010

3 Intake Filter ............................................................. 1 ........... FN317007000

4 Head Gasket .......................................................... 1 ........... FN116011037

5 Valve Holder Plate .................................................1...........FN116034100

6 Cylinder Gasket ..................................................... 1 ...........FN113113034

7 Cylinder ................................................................... 1 ........... FN116034006

8 Screw.......................................................................2...........FN014011064

9 O-Ring .....................................................................1 ........... FN010114000

10 Piston Ring Set ........................................................1 ...........FN216011003

11 Piston .......................................................................1 ........... FN116011027

12 Circlip ......................................................................2 ........... FN015001000

13 Gudgeon Pin ..........................................................1 ........... FN113113003

14 Complete Piston ....................................................1...........FN416011027

15 Connecting Rod ....................................................1 ........... FN116091021

16 Oil Dipstick ..............................................................1 ........... FN012036000

17 Complete Casing Cover ...................................... 1 ...........FN116032014

18 Cover Gasket .........................................................1 ........... FN116001025

19 Crankshaft .............................................................. 1 ...........FN116034004

20 Casing .....................................................................1...........FN116022051

21 Screw.......................................................................2 ........... FN116011038

22 Overload Reset 240V ............................................ 1 ...........FN008035000

22 Overload Reset 110V ............................................ 1 ...........FN008015000

23 Capacitor 240V .....................................................1 ........... FN009200014

23 Capacitor 110V .....................................................1 ........... FN009200026

24 Bearing ....................................................................1 ........... FN033018000

25 Rotor ........................................................................1...........FN034045000

26 Stator 240V ............................................................. 1 ........... FN416035605

26 Stator 110V ............................................................. 1 ........... FN416085601

27 Bearing ....................................................................1 ........... FN033118000

28 Rear Cover ............................................................. 1 ...........FN116011002

29 Fan ........................................................................... 1 ...........FN116001003

30 Housing ................................................................... 1...........FN199100070

31 Set Of Gaskets .......................................................1...........FN216GE0101

12

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.

WARNING! THIS APPLIANCE MUST BE EARTHED

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

following code:

Green & Yellow - Earth

Blue - Neutral

Brown - Live

As the colours of the flexible lead of this appliance may not correspond with the
coloured markings identifying terminals in your plug proceed as follows:

• Connect GREEN & YELLOW cord to terminal marked with a letter “E” or Earth
symbol “ ” or coloured GREEN or GREEN & YELLOW.

• Connect BROWN cord to terminal marked with a letter “L” or coloured RED.

• Connect BLUE cord to terminal marked with a letter “N” or coloured BLACK.

If this appliance is fitted with a plug which is moulded onto the electric cable (i.e.
non-rewireable) please note:

1. The plug must be thrown away if it is cut from the electric cable. There is a
danger of electric shock if it is subsequently inserted into a socket outlet.

2. Never use the plug without the fuse cover fitted.

3. Should you wish to replace a detachable fuse carrier, ensure that the correct
replacement is used (as indicated by marking or colour code).

4. Replacement fuse covers can be obtained from your local dealer or most
electrical stockists.

FUSE RATING

The fuse in the plug must be replaced with one of the same rating (13 amps) and
this replacement must be approved to BS1362.

We recommend that this machine is connected to the mains supply via a Residual
Current Device (RCD)

If in any doubt, DO NOT attempt any connections or repairs yourself. Consult a
qualified electrician, your Clarke dealer, or CLARKE International Service Dep’t on

020 8988 7400 or e-mail: [e-mail]

PIONEER 110 Volt model

Connect the mains lead to a suitable 110V (50Hz) electrical supply through an
approved plug or a suitably fused isolator switch.

If using a portable 110V transformer, make sure it has a rated capacity sufficient
to take a 13 amp load.

5

ASSEMBLY

1. Remove the plastic travel plug from the oil filling hole (fig.1) and insert the
dipstick (fig.2)

2. Remove the plastic dust cap from the hole in the side of the head, (fig 3), and
squirt a few drops of commonly available light oil (3 in 1 or similar), into the
cylinder head.

Fig. 1

Fig.3

Fig.2

Fig.4

PARTS LISTS

AND

3. Screw on the air intake filter (fig.4)

PREPARATION FOR USE

Check the oil level is at the correct level on the
dipstick, as shown in Fig.5. Where necessary, top up
with Clarke SAE40 Compressor Oil available from your
Clarke dealer.

6

DIAGRAMS

Fig.5

11

ACCESSORIES

OPERATION

Your Clarke Pioneer Air Compressor can be used in conjunction with a range of
optional accessories for inflating tyres, air brushing, stapling, blowing and many
other uses. For details contact your local accessory stockist.

A complete kit - Model KIT 1000, illustrated below, is available from your Clarke
dealer which is ideal for almost all applications.

Please quote part number 3110155

A similar kit is available, without the spray gun - Model KIT 600, Part No. 3110150
The accessories are also available separately
Should you experience any difficulties obtaining accessories, please contact the

Clarke sales department (telephone [phone]) for details of your nearest dealer.

SPARES AND SERVICING

1. Check that the mains voltage corresponds with that shown on the data sticker
on the crankcase cover of the machine.

2. Ensure that the ON/OFF knob on the Pressure Switch is pushed DOWN in the
‘OFF’ (O) position and then switch on at the mains supply.

3. To start the compressor pull the ON/OFF knob, UPWARDS to the ‘ON’ (l) position.

NOTE:
Should the motor fail to start

immediately it is probable that
the air receiver is already full of
air. Open the Air Outlet tap, and
trigger the air tool if fited, to
release air and the motor will
start automatically when the
tank pressure is reduced.

4. Before starting any work
allow the compressor to run
with the air outle cock
completely opened, to
permit a good distribution of
the lubricating oil.

5. Close the outlet tap.

6. Connect the air hose and
spraygun, or other air tool,
to the compressor outlet,
preferably using Quick Fit
couplings, readily available
from your Clarke dealer, then re-open the outlet tap.

Fig. 6

For Spare Parts and/or Servicing, please contact your nearest dealer, or

CLARKE International as follows:

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

10

6. Set the operating pressure by adjusting the pressure regulator. To do this, turn
the knob - clockwise to increase pressure and anti- clockwise to reduce it.

NOTE:
For normal spraying do not exceed 50 psi (unless following paint manufacturer’s
instructions). If other attachments are used, for example a tyre inflating gauge,
staple gun, paraffin gun etc, it may be necessary to set the operating pressure at
a higher (or lower) level. Please refer to the accessory manufacturers’
recommendations for optimum operating pressures for their equipment.

7

7. The Pressure Switch should not require adjustment. This is an automatic device
and has been pre-set at the factory to stop the motor when the pressure in
the receiver reaches its maximum (115 psi), and to start it again when the
pressure in the receiver falls to the minimum precept value. This operation is
completely automatic and does not affect the spraying process in any way.

MAINTENANCE

1. After the first 5 hours of running the compressor, check the cylinder head bolts
and motor housing, screws and re-tighten if any have worked loose.

NOTE:
If the machine pumps continuously without cutting-out then the compressor
is too small for the application/tool being used, and damage to the
machine may result.

SHUTTING DOWN THE COMPRESSOR

1. Press the ON/OFF switch to the off ‘O’ position.
NEVER USE THE MAINS SWITCH TO STOP THE MOTOR.

2. IMPORTANT!...... ALWAYS depress equipment trigger (spraygun) to release air

from the hose and compressor BEFORE disconnecting from the machine.

3. Switch off and disconnect from the mains supply.

2. Check the oil level every time you start working and top-up if necessary (use
Clarke SAE 40 compressor oil).

3. After the first 50 hours use, replace the
oil completely (use Clarke SAE 40
compressor oil) and then, after every 100
hours. To empty the oil from the
machine, remove the screw on the front
of the crankcase cover (fig.7).

4. Every 50 hours use, remove the black
plastic air filter (fig.8), then unclip the
back cover.

Remove the filter and wash it in clean
soapy water. Allow to dry completely
before reassembling. Renew the filter if
it is badly contaminated or damaged in
any way.

5) At least once a week drain the
condensate from the receiver by
unscrewing the drain plug underneath
the air receiver (fig.9).

NOTE: If the compressor is used on a daily
basis, then the tank should be drained before
each use.

Fig. 7

Fig.8

Fig. 9

8

6) In the event of an air leak follow the
procedure below:

• Load compressor to maximum pressure

• Unplug the compressor

• With a brush and soapy water wet all
‘screwed’ connections

• Any leaks will show through the
formation of air bubbles

NEVER UNSCREW A CONNECTION WHILE THE
RECEIVER TANK IS UNDER PRESSURE...ALWAYS
MAKE CERTAIN THAT THE TANK HAS FIRST
BEEN EMPTIED.

9