Clarke PP10ND Manuel d'installation et d'exploitation

1002©

Air Compressor

PP10ND • PPH10ND • PP15ND • PPH15ND

Operating & Maintenance

Instructions

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

International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: Parts@clarkeinternational.com

SERVICE: [email protected]

PARTS & SERVICE CONTACTS

SPECIFICATIONS

PP10ND PPH10ND PP15ND PPH15ND

Part Number 2090940 2090960 209080 2090100

Engine Type HONDA GX120 HONDA GX120 HONDA GX200 HONDA GX200

Pump Type MK101 MK101 MK103 MK103

Air Receiver size 50 litres 50 litres 50 litres 50 litres

Max. output Pressure 100psi 100psi 100psi 100psi

Air Displacement 9cfm 9cfm 15cfm 15cfm

Outlet connectors 1/4” BSP 1/4” BSP 1/4” BSP 1/4” BSP

Dimensions (mm) 940x410x780 1010x450x780 940x410x810 1010x450x810

Weight (kg) 71 62 70 74

Sound Power Level 99dBLWA 99dBLWA 98dBLWA 98dBLWA

NOTE:

Specifications are correct at the time of going to press. Clarke International

reserves the right to change specifications at any time, as it sees fit, in the interests

of safety or improvement in design.

- 17 -

- 2 -

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

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: Parts@clarkeinternational.com

SERVICE: [email protected]

Spare Parts and Service Contacts

If you have any problems using or setting up your Compressor

call the Clarke Helpline on,

020 8988 7400

Press 1 for Parts : 2 for Technical Assistance

WARNING!

DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS

DOING SO WILL INVALIDATE YOUR GUARANTEE

- 3 -

INTRODUCTION

Thank you for purchasing this Clarke portable compressor.

The unit is powered by a Honda engine, a manual for which,

is provided separately. Please refer to that manual for all

matters relating to the engine, ...starting and stopping

procedures, maintenance etc.

Read these safety instructions before using the equipment.

Guarantee ...................................................................................................................... 3

For your Own Safety ...................................................................................................... 4

Important General Notes .............................................................................................. 5

General Layout .............................................................................................................. 6

Preparation for Use ........................................................................................................ 7

Starting the Compressor................................................................................................ 8

Shutting Down the Compressor .................................................................................... 9

Maintenance................................................................................................................. 10

Parts Lists and Diagrams.............................................................................................11-13

Troubleshooting............................................................................................................. 14

Parts and Service Contacts ......................................................................................... 11

Troubleshooting............................................................................................................. 14

Specifications................................................................................................................ 17

Parts and service Contacts.......................................................................................... 17

CONTENTS Page

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.

- 18 -

- 4 -

FOR YOUR SAFETY

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:

General Precautions

ALWAYS

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

Operating Instructions supplied.

• stoptheengineandensurethepressureis expelled from the air receiver BEFORE carrying

out any maintenance.

• ensure that there is adequate ventilation when spraying flammable materials e.g.

cellulose paint, and keep clear of any possible source of ignition.

• 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.

• consult paint manufacturers instructions for safety and usage, before spraying

• ensure that the air supply is turned off at the machine outlet and all pressurised air from

the machine and other equipment attached to it, is expelled BEFORE disconnecting air

hoses or other equipment.

• make sure that children and animals are kept well away from the compressor and any

equipment attached to it.

• ensure that any equipment or tool used in conjunction with your compressor, has a

safety working pressure exceeding that of the machine.

NEVER

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

the skin. COMPRESSED AIR CAN BE DANGEROUS!

• leave pressure in the receiver overnight, or when transporting.

• adjust,ortamperwiththesafetyvalves. The maximum pressureis factoryset,andclearly

marked on the machine.

• operate in wet or damp conditions. Keep the machine dry at all times. Similarly, a clean

atmospherewillensure efficient operation. Donotuseindusty or otherwise dirty locations.

• touch the machine until it has cooled down...some of the metal parts can become

quite hot during operation.

• operate your compressor with any guards removed.

- 17 -

- 5 -

Fire Prevention

ALWAYS

•switch the engine OFF when refuelling.

•refuel away from any source of heat.

•refuel in a well ventilated area.

NEVER

•overfill the tank, fill to the level specified.

•smokewhilst refuelling and avoid smoking or using a naked flame nearthecompressor.

•start the engine if there is spilled fuel. Any spillage must be wiped clean and the

compressor allowed to dry before attempting to start the engine.

IMPORTANT General Notes

• NEVER allow anyone, not fully familiar with compressors, to use this equipment.

• DO NOT alter the engine settings....these settings are set at the factory. Should they

need recalibration - consult your Clarke dealer

Exhaust Gas Precautions

WARNING:

Exhaust fumes can be fatal

ALWAYS

• ensure there is adequate ventilation when using the compressor.

• position the compressor so that the exhaust is pointed away from people or animals .

NEVER

• use the compressor indoors or in an enclosed area. (i.e. in a warehouse, tunnel, well,

hold etc.)

Large amount of condensation in

air receiver.

Leaks in control unit or inspection

cover.

Too little pressure differential.

Compressor unit runs

on and off load more

frequently than usual.

Compressor unit runs

‘on load’ when no air is

being used.

Leaks in pipework system.

Compressor’s oil

consumption rising. Too much oil in compressor.

Sump over full.

Cylinder worn.

Oil in the air delivered.

Governor controlled unit running

off load for too long a period.

Intake air filter blocked.

Oil level rises although

no oil has been put in. Condensation in oil pump.

Piping installation incorrect.

Compressor taking in air which is

too warm.

Delivery temperature of air from

air receiver too high.

Condensation at outlet

points.

Drain off condensation AT LEAST

once a week. Locate leaks (by

means of soapy water) and

repair.

Adjust pressure switch.

Locate and repair leaks.

Check oil level 2 or 2 minutes after

stopping.

Change seal and inspect

packing surfaces. Repair or

replace defective parts.

Increase ventilation to air

compressor.

Cylinder worn.

Intake air filter blocked.

Leaks around crank case.

Working temperature of

compressor too high because of

insufficient cooling.

Semi-automatic unit: Load too

small. Convert to fully automatic

operation.

Replace worn parts or send

compressor pump for an

overhaul.

Change air filter.

Reduce oil to correct level.

Replace worn parts or send

compressor pump for an

overhaul.

Convert to automatic control.

Change air filter.

Compressor over dimensioned.

Consult your local dealer.

Obtain better fresh-air supply to

compressor.

a) Use a larger air receiver.

b) Insert an aftercooler.

- 16 -

Fig.1

- 6 -

Suction rendered difficult or

impossible at suction intake,

or the air being taken in is too

warm.

Pressure gauge defective.

Unit too small in relation to air

consumption.

Unusual noise from

compressor.

Larger fresh-air inlet.

Change pressure gauge.

Connect a supplementary

compressor or install a larger

model.

Have compressor overhauled or

replace it.

Tighten bolts.

Tighten flywheel.

Move unit to a more solid base.

Compressor worn.

Bolts loose.

Flywheel loose.

Unit installed on an unsuitable

base.

Bearings, piston rings or cylinder

worn.

Valve broken.

Bearings of electric motor worn.

Compressor

becomes too hot. See that sufficient air is supplied to

flywheel or fan of compressor and

that hot air is properly vented.

Insufficient ventilation.

Oil level too low (check 2 or 3

times after stopping).

Wrong direction of rotation.

Unit working at too high a

pressure.

Not fully unloading (Governor

control machines only).

Cooling air from flywheel fan must

blow against compressor.

Fault in valves (machine not

stopping).

Blown head gasket (machine

not stopping).

Dirt on cooling fins or suction

filter.

Check, clean/replace.

Check and replace gasket.

Clean cooling fins and suction

filter.

Reset to correct working pressure

detailed on unit.

Check pressure unloading genie,

adjust if necessary, check

valve(s).

Clean or that out non return

valve.

Connect to a supplementary

compressor or install a larger

model.

Non-return valve partly blocked.

Change valve parts.

Have motor bearing replaced.

Replace worn parts or change

compressor pump.

- 15 -

Fill with oil – see Page 10.

Compressor being overworked

and running continuously.

- 7 -

PREPARATION FOR USE

A. Environmental

• Ensure the compressor is sited on a firm level surface.

• Ensure the environment is dry and dust free.

• Ensure there is adequate ventilation for:

a) Air intake to compressor

b) Cooling for compressor pump

c) Engine exhaust gases.

B. Engine

Checkoilandfuellevelsand

avisualcheckofcomponents.Refertoengineservicemanual.

C. Pump

• Check

oil level on the Dipstick - to level marked.

D. Fuelling

Fill with unleaded petrol, according to the instructions within the engine manual.

• Ensure the fuel tap is set to the required position.

• Ensure The fuel hose and connectors are intact, in perfectly serviceable

condition and there is no leakage.

Note : Always use a funnel to fill the fuel tank so as to avoid accidental spillage of

fuel. If fuel is spilled it must be removed from the unit and surrounding area, before

attempting to start the engine.

E. Receiver

• Drainoffany condensate,byopening thedrain cock (seeFig. 1). Remember

to close the cock when completed.

NOTE: This should be carried out DAILY when the compressor is in constant use.

F. Air Hose & Air Tool

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

NOTE: Quick fit nuts are provided. These may be removed if a 1/4”BSP is required.

• Attach the air tool/spray gun to the air hose...If using snap couplings, use

a whip end, available from your Clarke dealer.

TROUBLE SHOOTING CHART

IMPORTANT

1. Any remedial work that may be required must be carried out by a qualified engineer.

2. Switch off the engine before removing any parts from the compressor.

3. Drain the Air Receiver before dismantling any part of the compressor unit’s pressure system.

4. If your compressor develops a fault do not use until the fault has been rectified.

5. For troubleshooting the engine, refer to the engine manual.

REMEDY

Stop engine and empty air

receiver. Clean or replace

Load Genie

Thaw Load Genie out (Unit must

be installed in frost-free place).

Have pressure switch changed

by an electrician.

Adjust pressure switch or safety

valve.

WARNING: DO NOT ADJUST

SAFETY VALVE ABOVE MAXIMUM

WORKING PRESSURE DETAILED.

SYMPTOM

Engine difficult to

start

PROBABLE CAUSES

Load Genie leaking

(compressor unit is on load

during start).

Non-return valve blocked,

possibly frozen up.

Compressor unit

constantly ‘on load’ Pressure switch defective.

Pressure switch set at a

pressure higher than the

safety valve’s opening

pressure.

Bleed valve under

pressure switch blows

whilst compressor is

not running.

Load Genie leaking.

Bleed valve under

pressure switch blows

whilst machine is

running.

Compressor constantly

‘on load’ and cannot

attain the working

pressure required.

Load Genie leaking.

CleanLoad Genie or replace.

Suction filter blocked.

Leak between compressor

block and air receiver leaks in

or near air receiver.

Valves blocked by dirt, paint,

dust or choked up.

Inspection cover or plug

leaking.

- 14 -

Clean Load Genie or

change pressure switch.

Change filter.

Tighten connection and repair

leak.

Clean or change valves.

Empty air receiver and

change seal.

PUMP PARTS

1 Screw

2 Lower Cover

3 Casing

4 Bearing

5 Seal

6 Front Cover

7 Screw

8 Flywheel

9 Washer

10 Screw

11 Screw

12 Washer

13 Rear Cover

14 Oil Dipstick

15 Screw

16 Crankshaft

17 Connecting Rod

18 Piston Ring Kit

19 Circlip

20 Gudgeon Pin

21 Piston

22 Complete Piston

23 Cylinder

24 Valve Holder Plate

25 Head

26 Filter Cartridge

27 Intake Filter

28 Screw

29 Conveyor

30 Screw

31 Complete Seal Kit

32 Manifold

33 Automatic Discharge Valve

10ND 15ND

014013054

113149015

113167001

033027000

010053000

113149008

014013021

013160010

014005001

113160011

014013082

014005025

113149009

012036000

014010044

113167003

113149004

213115002

015098000

113115025

113115026

413115026

113169002

413149080

113149050

017024000

317026000

014002041

113150002

014006121

213168001

014013054

113149015

113167001

033027000

010053000

113149008

014013021

013160010

014005001

113160011

014013082

014005025

113149009

012036000

014010044

113167003

113150004

213167001

015023000

116025006

113164009

413167006

113167002

413167005

113150022

017003000

317001000

014002041

113150002

014006121

213167002

116091024

011158000

No. Description Part No. Part No.

- 13 -

STARTING THE COMPRESSOR

1. Fully open the receiver drain cock, (located between the wheels).

2. Startthe engine, accordingtothe instructionscontained in the engineservice

manual, and allow to run for 10 minutes.

3. After a ten minute period, close the drain cock then ensure both air outlet

sliding valves are pushed fully INWARDS to close the outlet.

Pressure will build up in the receiver and eventually the air governor will

operatesothat theengineruns off load.The pressure registered on thepressure

gauge should be 100psi.

4. Slide the outlet taps outwards to allow air to escape from the outlets, and

slowly turn the pressure regiulator clockwise. Observe the pressure gauge.

When the pressure has dropped by approx. 20psi, the regulator will cut in

again. Close the sliding outlet valves and pressure in the air receiver will once

again increase

5. Finally, stop the engineand set the pressureregulator to zero pressure(turned

fully anticlockwise) and attach the air hose and air tool.

6. Open the sliding valves then set the pressure regulator to full pressure and

check for air leaks at the tool and connectors.

• Ifleaksareapparent, stoptheengine and setthe regulator tozeropressure

(fullyanticlockwise), press the trigger ofthe toolto ensureno air is present

in the airline, then rectify the problem before proceeding.

• If no leaks are evident, set the outlet pressure to the desired value and

proceed to use the air tool in accordance with the manufacturers

instructions.

- 8 -

Initial Start-up

Fig.2

STOPPING THE COMPRESSOR

At the end of the day, stop the compressor in accordance with the instructions in

the engine manual, then open the drain cock.

Close the air outlet by sliding both valves inwards.

Operate the air tool trigger or operating lever etc., to ensure there is no pressure

in the air line, then disconnect airline and tool.

WARNING!

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 relieved.

Finally, close the drain cock.

Take care not to touch the engine or pump as they remain hot for some time

after use.

When starting subsequently, start the machine as follows:

1. At the beginning of the day, open the drain cock and allow any condensate

to drain completely, then close the cock.

2. To ease starting, ensure there is no pressure in the pump outlet manifold by

opening the Bleed Valve (See Fig.2).

3. Connect the air hose to one of the outlets and the air tool and set the pressure

regulator to zero pressure (turned fully anticlockwise).

4. Start the engine in accordance with the instructions contained in the engine

service manual, then close the bleed valve and allow pressure to build up.

5. When the the regulator/cut-outhas operated, slide the outlet valveoutwards

fullythen adjustthe pressureregulatorso that thedesired pressureis registered

on the gauge.

6. Check for air leaksat thetool andconnectors...as above, before proceeding

- 9 -

PUMP PARTS

- 12 -

MAINTENANCE

DAILY

a. Drain Air Receiver of any condensate

b. Check engine oil level and top up where necessary. Ensure the dipstick

breather hole is not blocked.

c. Check pump oil level

WEEKLY

a. Clean Pump Air Filter

1. PP10ND

Unscrew pump air filter from inlet manifold. Remove cover and check air

filter. Washinwarmsoapywater ifnecessary, rinsethoroughlyand replace

when completely dry. If it is damaged in any way, replace. Clean the

plastic housing thoroughly before reassembly.

2. PP15ND

Turn Pump AirFilter coverand pullaway to reveal paper element. If badly

contaminated, replace. Remove any loose contaminants if any then

replace.

b. Clean the engine cooling fins.

6 MONTHLY

Repairs should only be carried out by a qualified engineer. If problems

occur, contact your Clarke dealer.

- 10 - - 11 -

PARTS LIST

HS17210-ZE0-822

HS98079-56846

PP10ND

PPH10ND PP15ND

PPH15ND

HS17210-ZE1-822

HS17218-ZE0-821 HS17218-ZE1-821

HS98079-56846

1. HS28442-ZH8-003

2. HS28442-ZH8-003

3. HS28462-ZH8-003

1. HS28442-ZH8-003

2. HS28442-ZH8-003

3. HS28462-ZH8-003

`5100610 `5100610

50mm Pressure Gauge 2000175 2000175

Safety Valve Complete 2000180 2000180

Drain Cock 2000220 2000220

V-Belt 2100061 2100063

Wheel 2100289 2100289

Wheel Retaining Clip 2100306 2100306

Soft Rubber Foot 2100313 2100313

Pump Complete. 1390080 (MK101) 1390085 (MK103)

Pulley 2100085 2100084

Engine complete 800047 (GX120QH) 800055 (GX200QH)

Manifold 3-way CBM45469000 CBM45469000

Air Receiver 1999705 1999705

2100177 2100177

Renew pump lubricating oil.

Drain pump by removing the drain

screw (Arrowed in Fig.3).

Replace screw and top up until oil is

level with the mark on the dipstick,

using SAE40 oil available from your

Clarke dealer as follows:

Compressor oil - 1 litre: Part No. 3050810

Compressor oil - 1 litre: Part No. 3050802

In addition to the above, check the engine manual for service

schedule.

Fig.3

Autres manuels pour PP10ND

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