Clarke Pioneer 210, 2320210 User guide

PIONEER OIL FREE COMPRESSOR

PIONEER OIL FREE COMPRESSOR

MODEL NO: 210 OF

PART No: 2320210

OPERATION & MAINTENANCE

INSTRUCTIONS

0903

CONTENTS Page

Specifications: ................................................................................. 1

Guarantee: ..................................................................................... 2

Safety Precautions.......................................................................... 3

Electrical Connections ................................................................... 4

Operating Instructions .............................................................. 5 & 6

Routine Maintenance .............................................................. 6 & 7

Accessories ..................................................................................... 7

Trouble Shooting ............................................................................. 8

Parts Diagram ................................................................................. 9

Parts List ......................................................................................... 10

Paint Spraying Hints .............................................................. 11 & 12

Notes .............................................................................................. 13

Declaration of Conformity .......................................................... 14

SPECIFICATIONS

Model: .................................................................... Pioneer 210 O/ F

Part No: ................................................................................ 2320210

Motor: ..................................................................................... 1.5 Hp

Voltage: ............................................................................... 230 vac

Fuse rating ............................................................................. 13amp

Air Displacement: ................................................................ 6.3 cfm

Max Working Pressure: ............................................................. 8 Bar

Air Receiver capacity: ............................................................... 6 ltr

Net Weight: .............................................................................. 13 kg

Dimensions: ............................................... L350 x W260 x H490mm

Duty Cycle ..................................................... S3-40% @ Max 7bar*

* The compressor may only be operated continuously for 4 minutes in any
period of 10 minutes, when output is max. 7 bar. (ie ; 4mins ON 6 mins OFF)

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 machines data plate

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NOTES

Please read these instructions carefully before operating the tool

Thank you for purchasing this CLARKE Pioneer Oil Free Air Compressor
Before using the device, please read this manual thoroughly and carefully follow
all instructions given. This is for your own safety and that of others around you, and
is also to help you achieve long and trouble free service from your new tool.

CLARKE 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 affect your statutory rights.

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PARTS & SERVICE TEL: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

ACCESSORIES

A wide range of Airline accessories is available, including Filter/Regulators, Lubricators, High
Pressure Hoses from 5 to 100 Metres, etc. Contact your CLARKE dealer for further information,
or CLARKE International Sales Department on 01992 565300

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SAFETY PRECAUTIONS

WARN IN G

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

4. DO NOT adjust, or tamper with the safety valves. The maximum pressure is factory set,
and clearly marked on the machine.

5. 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.

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

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

8. ALWAYS 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.

9. ALWAYS make sure that children and animals are kept well away from the compressor
`and any equipment attached to it.

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

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

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

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

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

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

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

For a professional looking finish paint must be thinned. If the manufacturers
recommendations on thinning are not available, the following can be used as a general
guide: Water based paints (emulsions) - 10-20% water

Oil based paints (gloss) - up to 10% white spirit thinners

Cellulose paints - up to 50% cellulose thinners

3. Handling The Gun

The first requirement for a good resultant finish is the proper handling of the gun. The gun
should be held perpendicular to the surface being covered and moved parallel to it. The
stroke should be started before the trigger is pulled and the trigger should be released
before the stroke is ended. This gives accurate control of the gun and material.

The distance between gun and surface should be 6 to 12 inches depending on material
and atomizing pressure. The material deposited should always be even and wet. Lap each
stroke over the preceding stroke to obtain a uniform finish.

NOTE: To reduce overspray and obtain maximum efficiency, always spray with the lowest
possible atomizing air pressure.

4. Spray Gun Maintenance

1. Immerse only the front end of the gun until solvent just covers the fluid connection.

2. Use a bristle brush and solvent to wash off accumulated paint.

3. Do not submerge the entire spray gun in solvent because:
a. the lubricant in the gland packings will dissolve and the packings will dry out.
b. the lubricant will dissolve causing harder operation and faster wear.
c. residue from dirty solvent may clog the narrow air passages in the gun.

4. Wipe down the outside of the gun with solvent dampened rag.

5. Lubricate gun daily. Use a light machine oil on:
a. fluid needle packing.
b. air valve packing.
c. fan control packing.
d. trigger pivot point.

Coat the fluid control spring with vaseline.

Caution: Never use lubricants containing silicone as this may cause finish defects.

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PAINT SPRAYING HINTS

ELECTRICAL CONNECTIONS

WARN ING

NEVER attempt to spray unless you are wearing suitable, approved respiratory and

eye protection.

REMEMBER that some modern paints require specialist respiratory protection...always

consult the paint manufacturers instructions.

1. General Preparation

a. Ensure that the area in which you will be spraying is clean and dust free.

b. Connect spray gun to compressor via suitable flexible hose.

c. With no paint in spray gun, test system for air leaks.

d. Cover adjacent pieces of equipment to prevent overspray. Mask areas

of the article not to be sprayed.

e. Ensure surface to be painted is clean, dry and free from oil and dust.

Check paint manufacturer’s instructions for any special surface
preparation required.

REMEMBER - TIME SPENT PREPARING SAVES TIME SPENT FINISHING

2. Paint Preparation

a. Achieve the correct paint viscosity. This should be done according to

paint manufacturer’s instructions, and will vary according to type of paint.

b. Having mixed the paint thoroughly in a separate container, pour into the

spray gun paint container through a fine filter.

DO NOT OVERFILL SPRAY GUN PAINT CONTAINER - three quarters full is maximum

c. It is usually best to experiment with a couple of practice spray coats on a

piece of material with the same type of surface as the article you wish to
spray, eg. metal for a car body panel, wood for a piece of furniture etc.

d. Some common problems:

PROBLEM CAUSE CORRECTION

Paint does not atomise Paint is too thick, air Add thinners. Increase air press.
(comes out in blobs) pressure is too low. (not above 50 psi, unless

specified by paint manuf.

Paint dries before hitting Paint is too thin. Air Add more paint.
surface, leaving it dry pressure is too high Reduce air pressure
with a rough texture

Finish is pitted like Air pressure too high Reduce air pressure,
Orange peel or spray too close to increase distance between
work gun and work.

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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.

IMPORTANT

If this appliance is fitted with a plug which is moulded onto the electric cable (i.e. non­rewireable) 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]

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OPERATING INSTRUCTIONS (Figures in brackets refer to Fig. 1 below)

Before connecting your Pioneer compressor to the mains supply, check the following:-

1. The mains voltage is 230V.

2. The ON/OFF control knob (D) is in the OFF (inner) position.

3. The pressure regulator (H) should be set at its lowest setting, by pulling knob upwards
and turning it fully anticlockwise to required pressure, push back down to lock in
position.

4. If the machine has not been used for 24 hours or so, open the air receiver drain valve
(B) and turn it on its end in order to drain any condensate which may have

accumulated. When clear, close the valve, finger tight. DO NOT rest the compressor

on the drain valve.

IMPORTANT

If the receiver is under pressure, keep your hands well away from the air being expelled....

remember, compressed air can be DANGEROUS!

G

Fig. 1

A

BC D E F

A. Air Receiver F. Mains Lead
B. Air Receiver Drain Valve G. Air Receiver Specification Plate
C. Non Return Valve H. Air Pressure Regulator Knob
D. ON / OFF Knob I. Quick Fit Coupling
E. Air Receiver Pressure Gauge

Connect a suitable air hose, fitted with a quick fit adaptor, to the quick fit coupling (I) on
the compressor.

On the other end of the air hose, fit the spray gun or air tool to be used, using a conventionall
¼” BSP connector and or quick fit coupling, DO NOT use snap couplings at the tool. If a
snap coupling is used, it must be connected via a whip hose.

Once the connections are complete, CHECK AGAIN to ensure the air pressure regulator
knob (I) is turned fully anticlockwise, plug the compressor into the mains supply and switch
and switch ON, switch the compressor ON by pulling the ON/Off Switch (B) out, until it clicks
into position.

The compressor will now start, and the pressure will build up in the receiver to a regulated
max, pressure of 8 bar (116 psi) the motor should then stop.

Should the motor fail to start immediately, this is probably because the receiver is already
fully charged, check the pressure gauge (E) . If you release some air, by opening the drain
valve (B), the motor should start automatically once the air pressure has dropped sufficiently,
ie; when the cut in pressure is reached.

H

Fig. 2

I

PARTS LIST (Pump)

Index No Part No Description Qty

1 FN116HP0001 Housing 1
2 FN116HP0002 Main Shaft 1

3 FN116HP0003 Crank 1

4 FN033047000 Bearing 1
5 FN034139000 Rotor 1
6 FN316HP1604 Stator 1
7 FN033005000 Bearing 1
8 FN116120007 Housing 1
9 FN014002154 Bolt 3
10 FN014003003 Nut 3
11 FN116120008 Fan 1
12 FN015083000 Circlip 1
13 FN014005069 Distance Piece 1
14 FN033055000 Bearing 1
15 FN416HP0004 Piston 1
16 FN116HP0005 Special Bolt 1
17 FN116120013 Gasket 1
18 FN014003001 Nut 2
19 FN416HP0007 Cylinder Head 1
20 FN014001056 Screw M8 2
21 FN009200004 Capacitor Compl. 1
22 FN008277000 Overload/Reset 1
23 FN011117000 Olive 1
24 FN116HP0011 Nut 1
25 FN116120017 Filter Element 1
26 FN116HP0008 Cover 1
27 FN116HP0009 Cover 1

PARTS LIST (Receiver)

50 FN126HB0012V 6lt Tank 1
51 FN022020000 Drain Cock 3/8” 1
52 FN020201000 Vibration Damper 3
53 FN129HU0011 Delivery Tube 1
54 FN014013042 Screw M5x15 2
55 FN347043000 Check Valve 1
56 FN047113001 Seal 1
57 FN047113002 Spring 1
58 FN010041000 Gasket 1
59 FN046001000 Rilsan Tube 1
60 FN011017000 Nipple 1/4” 1
61 FN321028000 Pressure Switch 1
62 FN101GA0200 Power Cable With BSI Plug 1
63 FN347022000 Safety Valve 1
64 FN330004000 Pressure Gauge Ø50-1/4” 1
65 FN011017000 Nipple 1/4” 1
66 FN319044000 Pressure Reducer With Line Cock 1

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PARTS DIAGRAM (Pump)

PARTS DIAGRAM (Receiver)

If the motor still fails to start, it is possible that the over load circuit breaker (Fig. 2) has tripped
out. This is a safety device to prevent the motor from overheating and eventually burning
out.

If the breaker has tripped, switch the compressor OFF by pushing the ON/OFF switch (D) in,
allow the machine to cool down before attempting to reset it.

Once the machine has cooled down sufficiently, push the circuit breaker reset switch (Fig.

2) in, switch the machine ON, by pulling the ON/OFF switch out, the motor should now run
and the air pressure should build.

If the motor still fails to start, check the fuse etc, if no apparent fault is found consult your
local CLARKE dealer.

IMPORTANT

As no outlet pressure gauge is fitted to this model, and the graduation marks on the pressure
regulator knob, provide an indication only of the output pressure. Therefore if the tools or
equipment that you are using are pressure sensitive, a pressure gauge should be inserted
into the airline to accurately regulate the output pressure.

When the compressor reaches its maximum working pressure (116 psi), the motor will
automatically cut out, and will restart when the pressure has fallen by approximately 20 psi.
This automatic STOP/START process will continue, as necessary to maintain pressure in the
air receiver.

Adjust the pressure regulator knob to the pressure required for the tool/equipment fitted.

Check to ensure that there are no air leaks at any of the couplings or any other part of the
system before operating the spray gun or air tool in the normal way.

When you have finished the job in hand ALWAYS switch OFF at the ON/OFF switch, NOT the
mains supply, and release any pressure remaining in the system by opening the drain valve
until all air is expelled.

ALWAYS operate the tool etc to further ensure that there is no pressure remaining in the
system before removing the tool. Finally, reset the pressure regulator to zero by turning the
knob fully anticlockwise.

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ROUTINE MAINTENANCE

IMPORTANT

Before carrying out any maintenance, ALWAYS switch OFF and disconnect the
compressor from the mains supply by removing the plug from the socket, drain
the air receiver and, if necessary allow the machine to cool down before starting
work.

Daily

ALWAYS before use, open the drain valve to expel any air left in the system, tip the compressor

onto its end and drain all condensate, if any, from the receiver, hold in that position until all
condensate has drained off. DO NOT rest the compressor on the drain valve.

Monthly

It is important to keep the compressor clean, to do this, use a small soft dusting brush and
vacuum cleaner. In particular, the air intake filter should be removed and inspected and
cleaned, in very dusty environments this should be carried out frequently.

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the performance of the machine, and even
shorten its life.

To clean the air intake filter, carefully remove the
sponge element shown in Fig. 3. clean the sponge
and the housing using a brush and/or clean lint
free cloth.

If necessary, the sponge may be gently washed
in warm soapy water, it must be rinsed and
allowed to dry thoroughly before refitting.

Fig. 3

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).

• Examine the non-return valve and renew if
necessary (fig. 4) (Item 55, page 9/10,)

TROUBLE SHOOTING

With considerate use, your CLARKE Air Compressor should provide you with long and trouble free
service. Routine checks should be made on both the electrical supply as well as the compressed
air lines and connections. If any fault appears, the reason for which is not immediately obvious,
please contact your local CLARKE Dealer.

PROBLEM

The compressor
stops and will not
start again.

PROBABLE CAUSE

Bad connections.

Overload cutout switch
has tripped.

Check electrical connections.
Clean and tighten as necessary.

Switch off and wait 5 minutes
before switching on.

REMEDY

• 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’ air connections

• Any leaks will show through the formation of air bubbles.

Fig. 4

WARN ING

NEVER unscrew a connection whilst the air receiver is under pressure.

ALWAYS make certain that the tank has been emptied.

ACCESSORIES

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

A suitable Spraygun and air hose is available for use with your Pioneer 210 oil free
compressor, part numbers as follows.

Spraygun PS .............................................. Part No. 5080813

Hose JP3 .................................................... Part No. 3120203

A wide range of accessories is available from your nearest CLARKE dealer, for further
information, contact your nearest dealer, or telephone CLARKE International Sales

department on 01992 565300.

Contact your local dealer for a
replacement motor.

Contact your CLARKE dealer.

Replace Piston (contact your
CLARKE dealer)

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

First drain the receiver completely.
Replace non-Return Valve

Replace Regulator

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

Compressor does
not start.

Air leaking from the
pressure switch valve
when the compressor
is not running.

Air pressure from
regulator will not
adjust.

Motor windings burnt out.

Compressor head gasket
blown or valve broken.

Worn Piston

Air receiver charged

Faulty non-return valve.

The diaphragm within the
regulator body is broken.

IMPORTANT:

The use of parts other than CLARKE replacement parts may result in safety hazards,
decreased tool performance and may invalidate your warranty.

CAUTION Do not attempt any repair or adjustment if you are uncertain as to how it should be done.
If you have any queries, contact your local CLARKE Dealer.

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