Clarke Pioneer 205 Operating & Maintenance Instructions

0503

PIONEER 205

OPERATING & MAINTENANCE

INSTRUCTIONS

PIONEER 205

2

SPARES AND SERVICING

Please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

15

SPARES AND SERVICING

Please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

3

Thank you for purchasing this Pioneer 205 Air Compressor which is fitted with a

9.5 litre 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

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

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

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

Operation ........................................................................................ 6

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

Maintenance .................................................................................. 8

Fault Finding .................................................................................. 10

Specifications ................................................................................ 11

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

Parts Lists and Diagrams ........................................................ 12 - 14

Parts and Service ................................................................... 2 & 15

14

PARTS LIST

No. Description Qty Part No.

1 Head Bolt 4 FN014002021
2 After Cooler 1 FN116117020
3 Cylinder Head 1 FN016055040
4 Air Filter Assy 1 FN317050000
5 Head Gasket 1 FN116117002
6 Valve Block 1 FN116022100
7 Bolt 2 FN014013021
8 O-Ring 1 FN010102000

9 Gasket 1 FN116022010
10 Bolt 2 FN014011064
11 Cylinder 1 FN116001004
12 Sealing Ring 1 FN010114000
13 Piston Ring Set 1 FN216022002
14 Piston 47 1 FN116022004
15 Gudgeon Pin 1 FN116022040
16 Circlip 2 FN015001000
17 Piston Complete 1 FN416022004
18 Con-Rod 1 FN116091021
19 Washer 1 FN014005006
20 Capacitor 1 FN009200015
21 Bearing 1 FN033018000
22 Shaft Assy 1 FN116032006
23 Gasket 1 FN116001025
24 Dipstick 1 FN012035000
25 End Housing 1 FN016032014
26 Screw 1 FN014013024
27 Screw 5 FN014006121
28 Bolt 2 FN116011038
29 Housing 1 FN116022051
30 Rotor 1 FN116032007
31 Stator 1 FN416033604
32 Bearing 1 FN033005000
33 End Housing 1 FN116011001
34 Nut 2 FN014003002
35 Fan 1 FN116001003

No. Description Qty Part No.

36 Cover 1 FN116117015
37 Reset Button 1 FN008040000
38 Washer 1 FN010072000
39 Filter Element 1 FN116055043

- Gasket Set Compl. 1 FN216HN0001

50Reservoir 1 N164A51000V

51 Retaining Ring 2 FN015018000
52 Wheel 2 FN020006000
53 Anti-Vibration Pads 2 FN116011006
54 Bolt 2 FN014006022
55 Drain Valve 1 FN022022000
56 Screw 4 FN014013042
57 Power Cable 1 FN101GA0200
58 V alve 1 FN347022000
59 Press. Gauge - Res. 1 FN330004000
60 Pressure Gauge - line 1 FN330006000
61 Washer 2 FN014005037
65 Output Reg. Assy 1 FN319013000
66 Adapter 1 FN011017000
67 Pressure Reg. Assy 1 FN321053000
68 Adapter 1 FN199110140
69 Connector 1 FN011248000
70 Tube 1 FN101HN0010
71 Anti-Vibration Pad 4 FN199575000
72 V alve 1 FN047113001
73 Spring 1 FN047113002
74 Valve Housing 1 FN010041000
75 Valve Assy 1 FN347043000
76 Handle 2 FN116022015
77 End Plug 2 FN011008000
78 Hose 1 FN046001000
79 Elbow 1 FN011055000
80 Tap Assy 1 FN322007000
81 Quick Release Coupl. 1 FN116011065

4

SAFETY PRECAUTIONS

WARNING

As with all machinery, there are certain hazards involved with their operation

and use. Exercising respect and caution will considerably lessen the risk of

personal injury. However, if normal safety precautions are overlooked, or

ignored, personal injury to the operator, or damage to property may result.

It is in your own interest to read and pay attention to the following rules:

1. COMPRESSED AIR IS DANGEROUS, NEVER direct a jet of air at people or animals,
and NEVER discharge compressed air against the skin.

2. DO NOT operate your compressor with any guards removed.

3. Electrical or mechanical repairs should only be carried out by a qualified
engineer. If problems occur, contact your Clarke dealer.

4. Before carrying out any maintenance, ensure the pressure is expelled from
the air receiver, and the machine is disconnected from the mains 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 machine.

7. DO NOT operate in wet or damp conditions. Keep the machine dry at all times.
Similarly, a clean atmosphere will ensure efficient operation. Do not use in
dusty or otherwise dirty locations.

8. Some of the metal parts can become quite hot during operation. Take care
not to touch these until the machine has cooled down.

9. Always adjust the pressure regulator to the recommended setting for the
particular spray gun or tool being used.

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

11. Protect yourself. Think carefully about any potential hazards which may be
created by using the air compressor and use the appropriate protection. e.g.
Goggles will protect your eyes from flying particles. Face masks will protect
you against paint spray and/or fumes.

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

13. Do not exert any strain on electrical cables and ensure that air hoses are not
tangled or wrapped around machinery etc.

14. When disconnecting air hoses or other equipment from your compressor ensure
that the air supply is turned off at the machine outlet and expel all pressurised
air from within the machine and other equipment attached to it.

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

16. Always ensure that all individuals using the compressor have read and fully
understand the Operating Instructions supplied.

17. Ensure that any equipment or tool used in conjunction with your compressor,
has a safety working pressure exceeding that of the machine.

13

COMPRESSOR

PIONEER 205

12

5

ELECTRICAL CONNECTIONS

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]

6

PREPARATION FOR USE

NOTE:

All numbered items throughout this manual refer to the parts list item number

on Page 14.

1. Remove the plastic travel plug from the oil filler hole, on the
top of the crank case, and insert the dipstick (see Fig. 6 - p.8).

2. Check the oil level is at the correct level on the dipstick, as
shown in Fig.1. Where necessary, top up with Clarke SAE40
Compressor Oil available from your Clarke dealer.

OPERATION

(Ref. Figs. 2 and 2A)

NOTE:

if you intend using your compressor for spraying, read also the Helpful

Hints on Spraying booklet - supplied with the machine.

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 is in the OFF (0) position, i.e. pushed DOWN,
then plug in and switch on at the mains supply.

3. To start the compressor pull UP the ON/OFF knob to the ON (I) position

- the motor should start immediately.

Note: Should the motor fail to start immediately, it is probable that the air receiver
is already full of air. Check the tank pressure gauge (see fig. 2). If you release air,
by opening air outlet tap, the motor will start automatically once the cut-in pressure
is reached.

4. Before connecting your
airline to the compressor,
allow it to run for 10 - 15
seconds, with the air outlet
tap completely open to
permit a good distribution
of the lubricating oil.

5. Close the outlet tap then
connect one end of
suitable air hose to the
compressor air outlet, and
the other end to the
equipment to be used.

Set the outlet pressure by

Fig.1

Fig. 2

SPECIFICATIONS

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

Max.Pressure ...................................................10 bar

Air Displacement ................................................ 200L/min (7 cfm approx.)

Electric Motor ................................................... 1.5 hp (1.1 kW)

Receiver ................................................... 9.5 Ltr

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

Fuse Rating ................................................... 13amps

Duty Cycle ................................................... S1 at max. 7 bar.

11

ACCESSORIES

Your Clarke Pioneer 205 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.

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

(i.e. Compressor may run continuously at 7 bar max.)

PROBLEM

PROBABLE CAUSE

REMEDY

The compressor
stops and will not
start again.

Bad connections.

Check the electrical
connections.
Clean and tighten as
necessary.

Blown fuse Renew/Replace fuse

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

Compressor head
gasket blown or valve
broken.

Wait for compressor to cool
down, disassemble the head
and replace any broken
components.
Carefully clean all sealing
surfaces before reassembling.
If in doubt contact your
nearest dealer.

NOTE: It is also possible that
you are using more air than
the compressor is capable of
delivering.

Compressor does
not start.

Air receiver charged

(see also item 1)

Open drain cock to expel air.
Compressor should start again
when pressure reduces to
approx 95 psi.

Air leaking from
the pressure switch
valvewhen the
compressor is not
running.

Faulty non-return
valve.

First drain the receiver
completely of air. Remove the
valve end plug, carefully clean
the valve seat and the gasket
and reassemble. See Fig 8.

Air pressure from
the regulator will
not adjust.

Replace RegulatorThe diaphragm within
the regulator body is
broken.

The compressor is
very noisy and
makes a metallic
knocking sound.

Return the machine to your

nearest service agent.

Compressor damaged
and needs overhaul.

Switch off and wait 5 minutes
before pressing the reset button.

Overload cutout
switch has tripped.

FAULT FINDING

10

7

adjusting the Output
Pressure Regulator. To do
this, turn the Pressure
Regulator Knob clockwise
to increase pressure,
anticlockwise to decrease.

Note: For most spraywork
do not exceed 50 psi
(unless following paint
manufacturers
instructions).

For other airline equipment
such as air tools, tyre
gauges, staple guns,
paraffin guns etc., it may
be necessary to set the
operating pressure at a
higher (or lower) level.

IMPORTANT:

Always refer to the accessory manufacturers recommendations

for optimum operating pressures for their equipment.

6. With operating pressure set, re-open the air outlet tap.

7. The Pressure Switch, located within the plastic cover beneath the ON/OFF
knob, should not require adjustment. This is an automatic device and has
been pre-set at the factory to stop the motor when pressure in the receiver
reaches its maximum, and to start it again when the pressure in the receiver
falls to the minimum preset value. This operation is completely automatic and
does not affect the spraying process in any way. However, should problems
develop with the cut-in, cut out settings, please consult your Clarke dealer, or
the Clarke Service Dept.

NOTE:

a. If the machine pumps continuously without cutting out then the compressor

is too small for the application/tool being used, and damage may result.
Consult your Clarke dealer.

b. The motor is protected by a Thermal

Overload so that if the motor
overheats for any reason - the
thermal overload will trip, stopping
the motor. To restart, allow a period
for the motor to cool down, before
pressing the Reset Button, illiustrated
in fig 2A and 3.

c. DO NOT exceed the Duty Cycle for

the machine (see Specifications).

Fig. 3

Fig. 2A

SHUTTING DOWN THE COMPRESSOR

1. To shut off the compressor, simply press DOWN on the ON/OFF knob (See
Fig. 2) . Always use this knob to shut down the compressor. NEVER USE THE
MAINS SWITCH TO STOP MOTOR.

2. Close the air outlet tap and trigger the equipment (spraygun, air tool etc.)
to release air from the air hose before disconnecting the hose from the
machine.

3. Before transporting your compressor or when leaving overnight, expel all air
from the receiver by opening the drain valve (55).

MAINTENANCE

A. DAILY

1. Drain any condensate that may have

accumulated in the receiver daily by un-
screwing the drain valve underneath the
air receiver (figs. 2 and 5).

2. Check the oil level before you start and

top up if necessary - (use Clarke SAE 40
compressor oil).

B. PERIODICALLY

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.

2. After the first 100 hours use replace the

oil completely using Clarke SAE 40
compressor oil. Thereafter replace the
oil completely after every 500 hours of
operation or every 6 months.
To empty the oil from the machine
remove the drain plug from the
crankcase cover (see figs. 2A and 6).

3. Every 50 hours (more frequently if used
in a dusty environment), clean the air
intake filter, by carefully prising off the
plastic filter from the air inlet, opening
the bottom flap, and withdrawing the
sponge element (see Fig 7).

Clean the sponge and the inner housing. If necessary, thesponge filter may
be gently washed in warm soapy water, rinsed and allowed to dry thoroughly

8

Fig. 6

Fig. 5

before refitting. Ensure that the outer
filter cover is then pushed back on to
the air inlet.
If any part of the filter is damaged
then you should obtain a
replacement.

4. Every 500 hours of operation or
every 6 months

 clean all the external parts of

the compressor.

(This cleaning makes the cooling
process more efficient and prolongs
the life of the machine).

 Check and clean the inlet and

outlet valves (consult your Clarke
dealer).

 Examine the non-return valve and

replace the gasket if necessary (fig. 8)

5. 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.

WARNING

NEVER UNSCREW A CONNECTION WHILST THE AIR RECEIVER IS UNDER PRESSURE.

ALWAYS MAKE CERTAIN THAT THE TANK HAS FIRST BEEN EMPTIED.

9

Fig. 7

Fig. 8

Parts List item No. 59