Clarke ZX 500, AIR ZX 500 Operation And Maintenance Instructions

OPERA TION & MAINTENANCE

INSTRUCTIONS

009050902

AIR COMPRESSOR

AIR COMPRESSOR

Model No: ZX 500

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Parts Drawing

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Thank you for purchasing this Clarke Air Compressor set, which is designed for indoor use
only.

Before attempting to operate the machine, please read this instruction manual thoroughly
and carefully follow all directions given. This is for your own safety and that of others around
you, and also to help you achieve long and trouble free service from your compressor.

Your Air Compressor can be used for a variety of applications including spraying paint and
other liquids, powering tools, inflating and cleaning where the average air consumption of
the tool being used does not exceed approximately 5 cubic feet per minute (5CFM).

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GUARANTEE

This product is guaranteed against faults in manufacture for 12
months from purchase date. Please keep your receipt as proof of
purchase.

This guarantee is invalid if the product has been abused or tampered
with in any way, or not used for the purpose for which it is intended.

The reason for return must be clearly stated.
This guarantee does not affect your statutory rights.

CONTENTS Page

Declaration of Conformity .................................................. 2

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

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

Operating Instructions.......................................................... 6

Maintenance ........................................................................7

Shutting down the compressor........................................... 8

Fault finding........................................................................... 8

Technical data ..................................................................... 9

Parts and Service Contacts................................................. 9

Parts List & Diagrams ................................................. 10 & 11

Parts List

No. Description

Qty

Part No No. Description Qty Part No

1 Head Bolt 4 TTZX50001
2 Spring Washer 4 TTZX50002
3 Cylinder Head 1 TTZX50003
4 Exhaust 1 TTZX50004
5 Gasket 1 TTZX50005
6 Valve Assy 2 TTZX50006
7 Valve Plate 2 TTZX50007
8 Spacer 1 TTZX50008
9 Piston 1 TTZX50009
10 Head Gasket 1 TTZX50010
11 Cylinder 1 TTZX50011
12 Crankcase Bolt 4 TTZX50012
13 Spring Washer 4 TTZX50013
14 Gasket 1 TTZX50014
15 Compression Ring 1 TTZX50015
16 Compression Ring 1 TTZX50016
17 Piston Ring 1 TTZX50017
18 Gudgeon Pin 1 TTZX50018
19 Circlip 2 TTZX50019
20 Con-Rod 1 TTZX50020
21 Crankshaft 1 TTZX50021
22 Bolt 1 TTZX50022
23 Breather 1 TTZX50023
24 Bolt 4 TTZX50024
25 Oil Sight Glass 1 TTZX50025
26 O-Ring 1 TTZX50026
27 Crank Case Cover 1 TTZX50027
28 Gasket 1 TTZX50028
29 Crankcase 1 TTZX50029
30 Washer 4 TTZX50030
31 Bolt 4 TTZX50031
31a Screw Nut 2 TTZX50031a
33 Capacitor 2 TTZX50033
33a Screw 2 TTZX50033a
33b Spring Washer 2 TTZX50033b
34 Rotator 1 TTZX50034
34a Bearing 2 TTZX50034a

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35 Stator 1 TTZX50035
35a Shaft Seal 1 TTZX50035a
36 Fan 1 TTZX50036
36a Circlip 1 TTZX50036a
37 Bearing Cover 1 TTZX500037

37a Bolt 2 TTZX50037a

38 Casing 1 TTZX50038
39 Bolt 4 TTZX50039
40 Air Cock 1 TTZX50040
41 Pressure Gauge 1 TTZX50041
42 Pressure Gauge 1 TTZX50042
43 Regulator 1 TTZX50043
44 Connector 1 TTZX50044
45 Safety Valve 1 TTZX50045
45a Pressure Switch 1 TTZX50045a
45b Pressure Switch Adj. 1 TTZX50045b
45c Bolt 1 TTZX50045c
45d Washer 1 TTZX50045d
46 Air Pipe 1 TTZX50046
46a Washer 1 TTZX50046a
46b Unloader Screw 2 TTZX50046b
47 Hand Grip 1 TTZX50047
48 Receiver 1 TTZX50048
48a Drain Cock 1 TTZX50048a
49 Check Valve 1 TTZX50049
49a Elbow 1 TTZX50049a
50 Cable 1 TTZX50050
50a Connector (Y) 4 TTZX50050a
50b Connector (O) 2 TTZX50050b
51 Power Cable 1 TTZX50051
52 Nut 4 TTZX50052
52a Spring Washer 4 TTZX50052a
53 Foot 4 TTZX50053
54 Washer 4 TTZX50054
55 Bolt 4 TTZX50055
56 Air Pipe Complete 1 TTZX50056
57 Air Cleaner compl. 1 TTZX50057

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:

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

the Operating Instructions supplied.

✔ ALWAYS ensure that any equipment or tool used in conjunction with your compressor,

has a safety working pressure exceeding that of the machine.

✔ ALWAYS adjust the pressure regulator to the recommended setting for the particular

tool being used.

✔ ALWAYS protect yourself. Think carefully about any potential hazards which may be

created by using the air compressor and use the appropriate protection. ALWAYS use
Goggles when operating a nailer or similar tool. Face masks will protect you against
paint spray and/or fumes.

✔ If spraying inflammable materials e.g. cellulose paint, ALWAYS ensure that there is

adequate ventilation and keep clear of any possible source of ignition.

✔ ALWAYS make sure that children and animals are kept well away from the compressor

and any equipment attached to it.

✔. ALWAYS, before spraying any material always consult paint manufacturers instructions

for safety and usage.

✔ ALWAYS , when disconnecting air hoses or other equipment from your compressor ensure

that air is shut off at the outlet and ALL pressurised air is expelled from the air line and
other equipment attached to it. (see ‘Operation’)

✔ ALWAYS expel air from the receiver and disconnect from the mains supply BEFORE

carrying out any maintenance.

✘ NEVER direct a jet of air at people or animals, and NEVER discharge compressed air

against the skin. COMPRESSED AIR CAN BE DANGEROUS,

✘ NEVER adjust, or tamper with the safety valves. The maximum pressure is factory set,

and clearly marked on the machine.

✘ NEVER leave pressure in the receiver overnight, or when transporting.
✘ NEVER operate your compressor with any covers removed.
✘ NEVER exert any strain on electrical cables and ensure that air hoses are not tangled

or wrapped around machinery etc.

✘ NEVER 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.

✘ NEVER touch metal parts of the machine as these can become quite hot during

operation. Wait until the machine has cooled down.

! Electrical or mechanical repairs should only be carried out by a qualified engineer. If

problems occur, contact your Clarke dealer.

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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

Accessories

A range of accessories, for inflating tyres, air brushing, stapling, blowing, paint
spraying etc., is available from your Clarke dealer.

NOTE:
If this compressor is supplied with an Air Nailer as part of KIT ZX500, then an 8
metre (25ft)Recoil Hose is also provided. Part No. 3110458

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Technical Data

Model ................................................................. ZX500

Maximum Air Pressure ....................................... 8 BAR - 116 PSI

Air Displacement ............................................... 5 CFM

Motor .................................................................. 1.25 HP

Voltage ............................................................... 230 VAC 50hZ 1pH

Motor Speed ...................................................... 2850RPM

Sound Power Level............................................ 82dBL

WA

Weight ................................................................ 20 kg (unpacked)

Part Number....................................................... 3110278

Dimensions (mm) ............................................... 490x235x545mm

Duty Cycle ......................................................... S3 50%**

**Duty Cycle...The motor on this machine may be run for 5

minutes only in any 10 minute period.

Parts & Service Contacts

For Spare Parts and Service, please contact your nearest dealer,

or CLARKE International, on one of the following numbers.

P ARTS & SERVICE TEL: [phone]

P ARTS & SERVICE FAX: [phone]

or e-mail as follows:

P ARTS: [e-mail]

SERVICE: [e-mail]

Electrical Connections

This product is provided with a standard 13 amp, 230 volt (50Hz), BS 1363 plug, for
connection to a standard, domestic electrical supply. Should the plug need changing at
any time, ensure that a plug of identical specification is used.

WARNING! THIS APPLIANCE MUST BE EARTHED

Should the plug need changing at any time, ensure that a plug of identical
specification is used. IMPORTANT: The wires in the mains lead should be wired up in
accordance with the following colour code:

Green & Yellow ..................... Earth

Blue ........................................ Neutral

Brown ..................................... Live

• Connect the Green & Yellow coloured cord to the plug terminal marked a letter

“ E ”or marked with the symbol “ ”

•

Connect the BLUE coloured cord to the plug terminal marked a letter “N”

• Connect the BROWN coloured cord to the plug terminal marked a letter “L”

FUSE RATING

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

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

If in doubt, consult a qualified electrician. Do not attempt any electrical repairs yourself.

CABLE EXTENSION.

Always use an approved cable extension suitable for the power rating of this tool (see
specifications), the conductor size should also be at least the same size as that on the
machine, or larger. When using a cable reel, always unwind the cable completely.

If this appliance is fitted with a plug which is
moulded on to 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

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fuse carrier, ensure that the correct replacement is used (as indicated by marking or
colour code).

4. Replacement fuse covers can be obtained from most DIY or electrical stores.

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MONTHLY

Start the compressor , and pressurise the system. Inspect all joints for leaks using soapy water,
and rectify as necessary.

EVERY 250 HOURS OR 6 MONTHS

(Whichever occurs first)

Change the compressor oil. Drain oil by removing the breather and turning the compressor
on to its end. Support it in this position and leave for a period to ensure all oil is drained.

Caution
Do not attempt any repairs or adjustments if you are uncertain as how it should be
done. If you have any queries, please contact your nearest CLARKE dealer, or
otherwise telephone CLARKE International, Service Department, on: 020 8988 7400).

1. Push the STOP/START switch down to the OFF position.
NEVER USE THE MAINS SWITCH TO STOP THE MOTOR.

2. Depress the tool’s trigger to release air from the hose and compressor before
disconnecting from the machine.

3. Switch off at the mains and remove plug.

Shutting Down The Compressor

Fault Finding

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

PROBABLE CAUSE

REMEDY

Motor windings burnt out.

Contact your local dealer for a
replacement motor.

Switch off and wait at least 5
minutes before trying to restart

Thermal Overload has
intervened.

The compressor
stops and will not
start again.

Bad connections. Check electrical connections.

Clean and tighten as necessary.

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

Compressor head gasket
blown or valve broken.

Broken piston

Contact your CLARKE dealer.

Replace Piston (contact your
CLARKE dealer)

Low Pressure Air Leak - safety Valve

Restricted air filter
Defective Check Valve

Blip safety valve by pulling the pull ring. If
condition persists See your Clarke dealer

Clean air filter, or replace
See your Clarke dealer

Operation

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

1. The Oil Filler Travel plug is removed and replaced with the breather supplied.

2. The machine is located on a level sur face in a clean dry environment with adequate

ventilation and plenty of air flow around the unit. DO NOT place any materials
whatsoever on the unit.

3. Check the oil level which should be at the red dot in the oil sight glass. If topping up is

required, refer to ‘Maintenance’.

4. Ensure the STOP/START switch is in the STOP position (Pressed fully Down).

5. The pressure regulator should be set to its lowest setting e.g. turned fully anti clockwise.

6. Check that the air receiver drain valve at the base of the receiver is fully CLOSED.

IMPORTANT: When using the compressor for the first time, open the drain cock and run the

compressor for at least 20 minutes, off load, in order for full lubrication to take place.

Now connect the air hose to the air outlet, and at the other end to the air tool - screwed on
directly.

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Once the hose connections are complete, plug in and start the compressor by pulling the
STOP/START switch upwards. Pressure will build up in the receiver, as indicated on the gauge,
to a predetermined maximum 116 PSI/8bar, when it will then stop.

At this point, slowly turn the pressure regulator clockwise to reach the desired setting for the
air tool to be used, as indicated on the Air Outlet Gauge.

Open the Air Outlet Tap and check to ensure there are no air leaks. Should leaks be
apparent, they should be rectified before proceeding.

Operate the air tool in the normal way. (Refer to the Air Tool manual). The air compressor
will restart when the pressure has fallen by approximately 20 PSI and this automatic STOP/
START process will then continue as necessary to replenish the receiver.

When you have finished with the compressor, always switch OFF at the STOP/START switch
on the machine, NEVER by switching OFF at the mains.

ALWAYS close the outlet tap and turn the pressure regulator fully anticlockwise, then operate

the trigger on the air tool BEFORE disconnecting the tool or air hose. NEVER attempt to
disconnect the tool or air hose before checking to ensure there is no air in the hose.

DRAIN VALVE

After a period of use, especially if the weather has been warm and humid, it is quite possible
that water (condensate), will have accumulated in the receiver.

To remove this condensate, first switch OFF the machine after ensuring that there is at least
some compressed air in the receiver.

Simply loosen the drain valve for a few moments allowing the air and any water to escape

- tip the machine over slightly so that the drain is the lowest point, to ensure all condensate
is drained. REMEMBER to ALWAYS Re-tighten the drain valve before storage.

Maintenance

IMPORTANT! Before carrying out any service work, ALWAYS disconnect the compressor
from the mains supply and release any air in the receiver. If necessary allow the
machine to cool down before proceeding.

It is most important to keep the Air Compressor clean, this can be carried out using a small
soft brush and a vacuum cleaner.

In particular the air filter should be inspected periodically, so that it is always kept clean. If
this instruction is not adhered to, a loss of performance could occur, even worse, any dirt
passing through the filter could make its way into the cylinder head and adversely affect
the valves. This could lead to more extensive damage necessitating its dismantling and
replacement parts etc.

BEFORE EACH USE

Drain any condensate which may be present in the receiver, Undo the drain cock and tilt
the machine so that the drain valve is at the lowest point in order to do so.

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THERMAL OVERLOAD

If the machine should overheat, the Thermal Overload will intervene and shut down the
compressor. Should this happen, switch OFF the machine by pushing the STOP/START switch
downwards, and wait for at least 5 minutes before starting again. It may take longer for the
overload to reset, depending upon conditions.

WEEKLY

1. Unscrew and remove the air filter assembly. Unclip the cover, remove the foam filter
and wash with warm soapy water. Allow to dry before reassembly. Renew if damaged.

2. Clean the fins of the compressor cylinder
and the cylinder head to receiver pipe. A
clean compressor will work more efficiently.

3. With the machine on a flat level surface,
check the oil level, It should be in the centre
of the oil sight glass, at the red spot. If
necessary, top up with SEA20 or SAE30 non
detergent oil, by unscrewing the breather
and using a small funnel to top up. Ensure
the hole in the breather is completely clear
before screwing back in place.

4. Check to ensure all nuts and bolts are tight.
Check cylinder head bolts which should be
tightened to 10lbf ft.