Clarke BOXER 100, Operation & Maintenance Instructions Manual

Page 1: ...1 OPERATION MAINTENANCE INSTRUCTIONS BOXER100 AIRCOMPRESSOR 0109 BOXER100 AIRCOMPRESSOR ...

Page 2: ...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 Preca...

Page 3: ... the air compressor WARNING Compressed air can be dangerous Death or serious injury could result from improper or unsafe use of this compressor To avoid these risks use your common sense and follow these basic safety instructions Compressed air should never be inhaled as it may contain toxic vapours or solid particles Always work in good ventilation especially when spraying paints or other toxic s...

Page 4: ...decompress before performing maintenance changing any parts and when not in use DO NOT ABUSE THE CABLE Never pull on the cable when removing the plug from the mains socket or lift the compressor by the mains cable BREATHING QUALITY AIR This compressor should not be used to supply breathing quality air DO NOT ABUSE THE COMPRESSOR Do not stand on the compressor SAFETY VALVE Never remove or attempt t...

Page 5: ...LVENT Do not use solvents or thinners such as petrol benzene carbon tetrachloride or alcohol to clean the air compressor as these chemicals will damage the finish With the air compressor unplugged from the supply use a dry cloth to wipe over the plastic casing KEEP ALL SCREWS AND COVERS TIGHTLY IN PLACE Check the screws and covers periodically ADEQUATE VENTILATION The compressor should only be use...

Page 6: ... of the compressor is damaged it should be carefully checked to determine that it will operate correctly and perform its intended function Check for the alignment of parts damage to parts air leaks and any other conditions that may affect its operation A guard or any other part that is damaged or defective should be properly repaired or replaced by an authorised service centre Defective pressure s...

Page 7: ...vent of a power cut and subsequent reset Do not carry the compressor while it is connected to the power source or when the tank is filled with compressed air This compressor contains surfaces which may reach a high temperature during operation Never operate with the motor housing removed Air and condensation water can burst from the compressor when the drain plug is removed Wear a safety goggles a...

Page 8: ...roceed as follows The wire which is coloured green and yellow must be connected to the terminal which is marked with the letter E or by the earth Symbol or coloured green or green and yellow The wire which is coloured blue must be connected to the terminal which is marked with the letter N or coloured black The wire which is coloured brown must be connected to the terminal which is marked with the...

Page 9: ... button 3 Reservoir pressure gauge 4 Output pressure regulator 5 Output pressure gauge 6 Handle 7 Support foot 8 Drain valve 9 Compressed air reservoir 10 Transportation wheel 11 Data Plate 12 Pressure regulator and cut out 13 Oil level indicator 14 Outlet tap 13 2 4 3 15 5 15 ...

Page 10: ...ighs 71kg After removing the compressor from its packaging make sure it has not been damaged in transit Positioning the air compressor This compressor should be positioned on a stable flat surface or one with a maximum inclination of 15O See figure 1 and ensure it is completely stable Do not cover or box in the compressor Always position it at least 50cm from any obstacle or wall Make sure the com...

Page 11: ...r to avoid damaging the valves or fittings The compressor is heavy get assistance when lifting and moving this compressor to avoid personal injury PREPARING FOR USE Before connecting your compressor to the mains supply Check the Oil 1 Make sure that the oil level is within the small circle on the oil level indicator See figure 2 If needed top up the reservoir with Clarke SAE 30 compressor oil avai...

Page 12: ...air is DANGEROUS WARNING Before connecting any air tool make sure you have read and fully understood the manufacturers instruction booklet for the tool being used Also ensure that the tool is compatible with the compressor and hose specifications The pressure regulator must be used to adjust the output pressure 1 Ensure that the red On Off switch is set to the OFF position pressed down See figure ...

Page 13: ...ank falls below a certain level 2 Check the operation of the safety valve under pressure daily by pulling the ring as shown in figure 6 Air should be released you pull the ring and stop when the ring is released If the valve does not operate as described or if the valve is stuck it must be replaced by qualified service personnel before using the compressor WARNING Do not remove or attempt to adjus...

Page 14: ... the power supply by pressing down on the on off button red button located on top of the pressure regulator and cut out 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 Reset button This compressor is equipped with a thermal overload device which operates as a safety device to protect the moto...

Page 15: ...g from the mains supply Place a suitable container beneath the compressor to catch any condensation 2 Carefully undo the drain valve anticlockwise until you hear a hissing noise this is the reservoir depressurising See figure 9 When the reservoir pressure gauge indicates zero and the hissing has stopped tighten the drain valve again OPERATING INSTRUCTIONS Figure 9 Drain valve ...

Page 16: ...ny liquid that may have condensed is drained off See page 15 Monthly The air intake filter should be inspected on a MONTHLY basis and more often in dusty conditions To clean the air intake filter 1 Pull the filter cover away from the compressor as shown See figure 10 2 Remove the sponge filter from the filter cover See figure 11 3 Clean the sponge and the filter cover using a soft brush If necessa...

Page 17: ... 100 hours use replace the oil completely using Clarke SAE30 compressor oil Then replace the oil after every 500 hours of operation or every 6 months To empty the oil from the machine remove the oil drain plug from the crankcase cover Non Return Valve Examine the non return valve and replace the gasket and valve if necessary Figure 12 Figure 13 Figure 14 ...

Page 18: ... take out the worn or broken drive belt 2 Place the replacement drive belt over the small wheel See figure 16 3 Position part of the drive belt over the large belt wheel as shown in figure 17 4 Rotate the large belt wheel by hand in a anticlockwise direction whilst guiding the belt on to the belt wheel Figure 16 Figure 17 Figure 15 ...

Page 19: ...e d a e h r o s s e r p m o C e v l a v r o n w o l b t e k s a g n e k o r b o t r o s s e r p m o c r o f t i a W e l b m e s s a s i d n w o d l o o c y n a e c a l p e r d n a d a e h s t n e n o p m o c n e k o r b g n i l a e s l l a n a e l c y l l u f e r a C e r o f e b s e c a f r u s t b u o d n i f I g n i l b m e s s a e r e k r a l C r u o y t c a t n o c r e l a e d s e o d r o s s ...

Page 20: ...eceiver 100 litre Net Weight 71kg Dimensions L x W x H 1220 x 460 x 810 mm Duty Cycle S1 continuous Part No 2225460 Please note that the details and specifications contained herein are correct at the time of going to print However we reserve the right to change specifications at any time without prior notice Always consult the machine s data plate ...

Page 21: ...21 PARTS DIAGRAM ...

Page 22: ...ER FN199763000 61 NUT FN014003001 62 SCREW FN014001049 63 HANDLE FN199426000 64 LOCKNUT FN199437000 65 DELIVERY PIPE FN113175009 66 COMPASS FN011304000 67 RILSAN TUBE FN046001000 68 SEAL FN047113001 69 TAPERED SPRING FN047113002 70 O RING FN010041000 71 CHECK VALVE FN347043000 72 MOTOR 230V 240V 50HZ FN540E001604 73 SAFETY VALVE FN048208000 74 NIPPLE FN011017000 75 PLUG FN011018000 76 PRESSURE SWI...

Page 23: ...23 ...

Page 24: ......