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1. au 4 a gr Air Compressor Models CFPOHND C Operating amp Maintenance Instructions WARNING DO NOT ATTEMPT TO ALTER ENGINE SPEED SETTINGS DOING SO WILL INVALIDATE YOUR GUARANTEE SPECIFICATIONS CFP9ND Part Number 2090901 Engine Type HONDA Pump Type MK238 Air Receiver size 2 65litres Max output Pressure 100psi Air Displacement 9cfm Outlet connectors 1 4 BSP Dimensions mm 520x360x440 Weight kg 21 G teed Sound Power Level 96 5cBL See Declaration of Conformity on Back Cover NOTE Specifications are correct at the time of going to print Clarke International reserves the right to change specifications at any time as it sees fit in the interests of safety or improvement in design Copyright Clarke International All rights reserved June 2002 Read these safety instructions before using the equipment ININODUO ON Thank you for purchasing this Clarke Air portable compressor The unit is powered by a 5HP 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 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
2. CIGCIID rara eel FNO15001000 20 PISTON Complete iii rca c RARS FN416022004 21 A 200 AAN FN116091021 22 A E FNO12035000 23 WASET trabas tedio da FNO10072000 24 SCIEW MIXTO earn id FNO14013024 25 ENC GSA aut dea Terr data atea FNO16032014 26 A OT FNO14006083 27 Cae 4250900202 EN FN116001025 28 ti tica E E cans tenets FNO14022001 29 ECCOMI Cupra stato oe FN 116060005 30 A E E E Ae FN 116060006 3il Cronista teatre A FN 116060001 32 BEANN tirita airis ceci i FNO33058000 33 O a tao annie a FNO10060000 34 CHONK COSC dota FN11606001 1 35 CAM ti dada ad FN 116060003 36 SCIEW MOX20 sais a aiaa aa ani eR o ERREEN FNO14013046 87 SCIEW MOX25 erinnere ua neh red FNO14013045 38 Ani a ana FNO16060002 39 EMC CSING anna FN116060004 40 Sele banca ceauiny seenucdasnceitegads sects vc E FN116060010 41 G sketKiin nan nennen er FN216GA0001 PARTS LIST ENGINE HS17211 ZL8 000 HS98079 56846 1 HS28400 ZL8 013ZA 2 HS28462 ZL8003 RECEIVER AND ANCILLIARY PARTS E N T CFP9HND J O 01 L N 11 12 13 14 15 16 Pump MK 238 Engine Honda 5HP Drain Cock Bottom Entry Gauge Safety Valve Manifold 4 way Rubber Foot Regulator Assy Back Entry Gauge 1 2 Load Genie 15mm Whee Wheel Retaining Clip Rubber Foot Mini Filter Regulator Manifold 3 way 1370005 Contact Spares Department 2000221 2000171 2000192 FN011276000 FN116011006 FN347026000 N A N A N A N A N A N A N A INTE
3. 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 SO Nils NS Page Introduchi n imita 4 E nenne heisse 4 ISA 5 Important General NOS ss cicsccciscesisscsvceccvecbesidercsesdecancucstycovecsvdeidavssesstserdssctvassenvsvcetvas 6 General LAYOUT AAA ceceuesssedsceestes 7 Preparation for USO six cae 8 Starting amp Using your Air CompresSsOr oooonccncononncicnnncncncncnononnn cnn nnnn cnn nan n rro n narran 00000000 9 Shutting Down the Compressor Maintenance SRRRBENTPREFPEBFFERRERFREFEFREPERMESEFRERFERFFREEFTFFERSFIEFESTEREETEFEFEEEEFTEERFEFSITSPIIPERTENPFUFFFERFERE 11 TROUDIGSMOONING iii ae Parts and Service Contacts Parts Lists and DIAGraMS 2 lt cessesecseccessencecenstecteecessncencencunsectecdescecsecszerssanecuencerse Declaration Of Conformity i cciiecsissssccscccsccescessectassecavsscscssccsscccesensecsassesassssesseeveseasszexs 18 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 fo property may result It is in your own interest to read and pay attention to the following rules General Precautions INN INES e e
4. on cooling fins or suction filter Unit working at too high a pressure Non return valve partly blocked Compressor being overworked and running continuously flywheel or fan of compressor and that hot air is properly vented Fill with oil see Page 10 Contact Clarke Service Department Contact Clarke Service Department Clean cooling fins and suction filter Contact Clarke Service Department Clean or that out non return valve Connect to a supplementary compressor or install a larger model Compressor unit runs on and off load more frequently than usual Large amount of condensation in air receiver Leaks in system Drain off condensation Regularly Every day before use Locate leaks by means of soapy water and repair Compressor unit runs on load when no air is being used Leaks in system Locate leaks by means of soapy water and repair Compressor s oil consumption rising Too much oil in compressor Leaks around crank case Working temperature of compressor too high because of insufficient cooling Cylinder worn Intake air filter blocked Check oil level 2 or 3 minutes after stopping Contact Clarke Service Department Increase ventilation to air compressor Contact Clarke Service Department Clean or replace Oil in the air delivered Sump over full Cylinder worn Intake air filter blocked Reduc
5. RNATIONAL This is an important document and should be retained DECLARATION OF CONFORMITY We declare that this product complies with the following standards directives HM 98 37 EC HM 2000 14 EC ANNEX VI PROCEDURE 1 HM 87 404 EEC Notified Body A V Technology Ltd Place Cheadle Heath Stockport SK3 OXU Tech File held at Clarke Int l Service Centre Shrubland Rd London E10 7RB Sound Power Level Power Level crP9HND 95 5dBL 96 54BL y Description ENGINE DRIVEN AIR COMPRESSOR Serial No 7 Signed gt Manage a Date 19 March 2007 i AN B S INTERNATIONAL Hemnall Street Epping Essex CM16 4LG DOC No HO75 27 Clarke International is a trading style of Clarke International Limited 19 A SELECTION FROM THE VAST RANGE OF fare QUALITY PRODUCTS AIR COMPRESSORS From DIY to industrial Plus air tools spray guns and accesories GENERATORS Prime duty or emergency standby for business home and leisure POWER WASHERS Hot and cold electric and engine driven we have what you need WELDERS Mig Arc Tig and Spot From DIY to auto industrial METALWORKING Drills grinders and saws for DIY and professional use WOODWORKING Saws sanders lathes mortisers and dust extraction HYDRAULICS Cranes body repair kits transmission jacks for all types of workshop use WATER PUMPS Submersible electric and engine driven for DIY agriculture and industry POWER TOOLS Angl
6. aper element If badly contaminated replace Remove any loose contaminants if any then replace b Clean the engine cooling fins 6 MONTHLY Renew pump lubricating oil and EAE Make sure the cylider head bolts are tight see below 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 SAE30 oil available from your Clarke dealer as follows Part No 3050801 In addition to the above check the engine manual for service schedule Repairs should only be carried out by a qualified engineer If problems occur contact your Clarke dealer Torque values for cylinder head bolts TROUBLE SHOOTING CHART IMPORTANT 1 Any remedial work that may be required must be carried out by a qualified engineer Switch off the engine before removing any parts from the compressor Drain the Air Receiver before dismantling any part of the compressor unit s pressure system If your compressor develops a fault do not use until the fault has been rectified aR amp N For troubleshooting the engine refer to the engine manual SYMPTOM PROBABLE CAUSE REMEDY Engine difficult to Load Genie leaking Stop engine and empty air start compressor unit is on load receiver Clean or replace during start Load Genie Load Genie valve blocked Thaw Load Genie out Unit must possibly frozen up be installed in frost free place Compresso
7. e grinders cordless drill sets AS saws and sanders STARTERS CHARGERS All sizes for car and commercial use For spare parts and servicing please contact your nearest dealer or Clarke International on 020 8988 7400 e mail Parts clarkeinternational com e mail Service clarkeinternational com INTERNATIONAL Hemnall Street Epping Essex CM16 4LG
8. e oil to correct level Contact Clarke Service Department Clean Change air filter Oil level rises although no oil has been put in Condensation in oil pump Compressor over dimensioned Condensation at outlet points Piping installation incorrect Compressor taking in air which is too warm Consult your local dealer Obtain better fresh air supply to compressor For Spare Parts and Service please contact your nearest dealer or CLARKE International on one of the following numbers PARTS amp SERVICE TEL 020 8988 7400 PARTS amp SERVICE FAX 020 8558 3622 or e mail as follows PARTS Parts clarkeinternational com SERVICE Service clarkeinternational com PUMP PARTS PUMP PARTS To Deen PO No Air Filter ASSY riirii tunnan hinaia aiaa FN317013000 2 Head Bolt M6X45 ein aa FNO14002021 3 Cylinder Heads nn ee FN116001001 4 SPO e urna da E ai FN116060015 5 Heath aia FN 116060016 6 Stew M6X7O ainia FNO14002029 7 Washer 6 SXI Bu FNO14005044 8 SCIEW MIX TS ent FNO14013042 9 EIDO Winora en an ae FNO1 1015000 10 Caio ad FN116022009 11 Vale Plain riada FN116022100 12 O nivale en Ca CROS FN116022010 13 CVINA iia FN116022001 14 SCIEW M8X20 aiii FN014011064 15 O RING eeren e a EE ENS ENEG FNO10114000 16 PISTON RING SET aia tren davai FN216022002 17 PISTOM M0906266 ernennen ne aie FN116022004 18 GUAS N PIN nenne FN116022040 19
9. ion consult your Clarke dealer GENERAL LAYOUT Pump Oil Dipstick Compressed Air Connections amp Oil Drain Controls Air Drain Cocks gt lt Frame Air Receiver CFP9ND 7 PREPARATION FOR USE e Ensure the compressor is sited on a firm level surface e Ensure the environment is dry and dust free e Ensure there is adequate ventilation for a Air intake to compressor pump b Cooling for compressor pump c Engine exhaust gases Check oil and fuel levels and a visual check of components Refer to engine service manual e Check oil level on the Dipstick to level marked D Fueling S Fill with unleaded petrol according to the instructions within the engine manual Ensure the fuel tap is set to the required position e Ensure The fuel hose and connectors are intact in perfectly servicable 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 Drain off any condensate by opening the drain cock see Fig 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 amp Air Tool e Attach the air hose to the outlet using an appropriate connector NOTE Quick fit nuts are provided with model PP9ND At
10. nsure that all individuals using the compressor have read and fully understand the Operating Instructions supplied Stop the engine and ensure the pressure is expelled from the air receiver BEFORE carrying out any maintenance e 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 soray and or fumes Ear defenders will prevent hearing damage caused by load noise 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 e 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 adjus
11. r unit Load Genie defective Have Load Genie serviced or constantly on load replaced Load Genie set at a pressure Contact Clarke Service higher than the safety Department valve s opening pressure Load Genie leaking Contact Clarke Service Department Compressor Suction filter blocked Clean Change filter PER en eRe Leak between compressor Tighten connection and and cannot attain A i i i repair leak the working pressure block and air receiver leaks in p or near air receiver required Valves blocked by dirt paint Contact Clarke Service dust or choked up Department Inspection cover or drain plug Empty air receiver and leaking change seals plugs Pressure gauge defective Change pressure gauge Unit too small in relation to Use a larger capacity air consumption compressor Compressor worn Have compressor overhauled or replace it Unusual noise from Bolts loose Tighten bolts compressor Flywheel loose Tighten flywheel Unit installed on an unsuitable Move unit to a more solid base base Bearings piston rings or cylinder Contact Clarke Service worn Department Valve broken Contact Clarke Service Department Compressor Insufficient ventilation See that sufficient air is supplied to becomes too hot Oil level too low check 2 or 3 times after stopping Fault in valves machine not stopping Blown head gasket machine not stopping Dirt
12. s Connect the air hose to the air outlet and tool and set the pressure regulator to zero pressure turned fully anticlockwise Start the engine in accordance with the instructions contained in the engine service manual and allow pressure to build up When the pressure in the receiver has built up and air blows off at the bleed hole turn the outlet pressure regulator clockwise so that the desired pressure is registered on the pressure gauge and proceed to use the air tool spray gun Check for air leaks at the tool and connectors as above before proceeding STOPPING THE COMPRESSOR At the end of the day stop the engine in accordance with the instructions in the engine manual then open the drain cock 1 Turn the regulator fully anticlockwise 2 Operate the air tool trigger or operating lever etc to ensure there is no pressure in the air line then disconnect airline and tool 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 3 Finally close the drain cock Take care not to touch the engine or pump as they remain hot for some time after use MAINTENANCE DAILY Drain Air Receiver of any condensate Check engine oil level and top up where necessary Ensure the dipstick breather hole is not blocked c Check pump oil level o QL WEEKLY a Clean Pump Filter 1 Turn Pump Filter cover and pull away to reveal p
13. t or tamper with the safety valves The maximum pressure is factory set and clearly marked on the machine 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 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 Ba ALWAYS e switch the engine OFF when refuelling e refuel away from any source of heat e refuel in a well ventilated area NEVER e overfill the tank fill to the level specified smoke whilst refuelling and avoid smoking or using a naked flame near the compressor e 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 Exhaust Gas Precautions INNING e ensure there is adequate ventilation when using the compressor position the compressor so that the exhaust is pointed away from people or animals NEVER WARNING Exhaust fumes can be fatal e Do not use the compressor indoors or in an enclosed area i e in a warehouse tunnel well hold etc IMPORTANT General Notes NEVER allow anyone not fully familiar with compressors to use this equipment e DO NOT dlter the engine settings these settings are set at the factory Should they need recalibrat
14. tach the air tool spray gun to the air hose If using snap couplings use a whip end available from your Clarke dealer STARTING AND USING THE COMPRESSOR First time startup NOTE For first time operation do not connect the air hose or any tools and proceed as follows I Start the engine according to the instructions contained in the engine service manual and allow to run for 10 minutes Em After a ten minute period stop the Receiver engine and attach an air hose to Pressure the air outlet and the tool Screw the pressure regulator fully anticlockwise then restart the engine and allow presure to build up in the receiver Screw the pressure regulator clockwise until the pressure registered on the Pressure Gauge is 100psi At this point check the system for air leaks If any are apparent stop the engine and operate the tool until the air pressure is at zero or open the drain cocks before rectifying Air Outlet NOTE Air will blow off at the bleed hole when the pressure reaches 100psi which is the MAX operating pressure 4 With the engine running turn the pressure regulator so that your desired pressure is registered on the gauge and proceed to use the air tool in accordance with the manufacturers instructions When starting subsequently start the machine as follows 1 At the begining of the day open the drain cocks see Fig 1 and allow any condensate to drain completely then close the cock
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