Instruction Manual for airmaster models including: AIRMASTER 18-150, 2245310, 2245310 Airmaster Compressor, 2245310, Airmaster Compressor, Compressor
Adequate ventilation for: • Air intake to the compressor. • Cooling for the compressor and its electric motor. ... AND BEFORE YOU PUT YOUR COMPRESSOR INTO STORAGE ...
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DocumentDocument150L BELT-DRIVEN AIR COMPRESSOR MODEL NO: AIRMASTER 18/150 PART NO: 2245310 OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS GC0724 rev 3 INTRODUCTION Thank you for purchasing this CLARKE Air Compressor. Before attempting to operate the machine, it is essential that you read this manual thoroughly and follow all instructions given. This will ensure the safety of yourself and others and you can look forward to the product giving you long and satisfactory service. 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 effect your statutory rights. ENVIRONMENTAL RECYCLING POLICY Through purchase of this product, the customer is taking on the obligation to deal with the WEEE in accordance with the WEEE regulations in relation to the treatment, recycling & recovery and environmentally sound disposal of the WEEE. In effect, this means that this product must not be disposed of with general household waste. It must be disposed of according to the laws governing Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal facility. 2 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SAFETY PRECAUTIONS Before using your compressor it is in your own interest to read and pay attention to the following safety precautions. 1. Compressed air is dangerous. DO NOT point a jet of air at persons or animals, and do not discharge compressed air against the skin. 2. DO NOT operate your compressor with the guard removed. 3. Repairs must only be carried out by a qualified engineer. If problems occur, contact your CLARKE dealer. 4. Before carrying out any maintenance make sure that the pressure is released from the air reservoir and that the compressor is disconnected from the electrical supply. 5. DO NOT leave pressure in the receiver overnight or when transporting. 6. DO NOT adjust or tamper with the safety valves. The maximum pressure is factory set, and clearly marked on the compressor. 7. DO NOT operate in wet or damp conditions. Keep the compressor dry at all times. Similarly, clean air will allow the compressor to work efficiently. DO NOT use in dusty or otherwise dirty locations. 8. Some of the metal parts can become quite hot during operation. DO NOT touch/remove these until the compressor has cooled down. 9. ALWAYS set any pressure regulator to the recommended setting for the tool. 10. When spraying flammable materials e.g. cellulose paint, ensure that there is sufficient airflow and keep clear of any source of ignition. 11. Before spraying any material always consult paint manufacturers instructions for safety and usage. 12. Protect yourself. Goggles will protect your eyes from flying particles. Face masks will protect you against paint spray and fumes. 13. DO NOT apply strain to electrical cables and make sure that air hoses are not kinked or wrapped around the compressor. 14. When disconnecting air hoses or other equipment from your compressor, make sure that the air supply is turned off at the outlet and vent all pressurised air from within the reservoir and other equipment attached to it. 15. Make sure that children and animals are kept well away from the compressor and any equipment attached to it. 16. Make sure that all individuals using the compressor have had any necessary training and have read and fully understand these operating instructions. 17. Make sure that any equipment or tool used in conjunction with your compressor, has a safe working pressure exceeding that of the compressor. 18. Be careful when transporting the compressor to prevent tipping over. 19. Permanently installed systems must be installed by a competent engineer. 20. These compressors produce noise levels in excess of 70dB(A). Persons working near the compressor must be supplied with ear protection. 3 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SAFETY SYMBOLS Readthisinstructionbookletcarefullybeforepositioning,operatingor adjusting the compressor. Risk of electric shock. The compressor must be disconnected from the mains supply before removing any covers. DO NOT use in a damp environment. Riskofaccidentalstart-up.Thecompressorcouldstartautomaticallyin the event of a power cut and subsequent reset. DO NOT move the compressor while it is connected to the power source, or when the tank is filled with compressed air. Thiscompressorcontainssurfaceswhichmayreachahightemperature during operation. NEVER operate with the motor housing removed. Wear safety goggles when using this compressor Wear ear protectors when using this compressor This compressor produces a high sound level during operation. 4 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INSTALLATION Before installing your compressor, confirm that its output will be sufficient for the airline equipment to be used. We recommend the following: 1. A firm, level site and the use of floor mountings with anti-vibration pads. (Do not bolt the machine directly to the floor). 2. A dust and damp free environment. 3. Adequate ventilation for: · Air intake to the compressor · Cooling for the compressor and its electric motor. 4. Sufficient access for servicing. (A minimum clearance of 500mm must be allowed around the machine). 5. The power cable must be adequate to carry the starting and running load of the electric motor. This is particularly relevant if the compressor is some distance from the source of supply. 6. Electrical installations should be completed by a qualified electrician. ELECTRICAL CONNECTIONS WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS SUPPLY. This compressor requires a 32A plug and connection to a MCB Type C meeting the requirements of BS EN 60309 and having a rated capacity of greater than 32 Amps. A standard 13 Amp (BS1363) plug must NOT be used. WARNING: THIS APPLIANCE MUST BE EARTHED. IMPORTANT: The wires in this mains lead are coloured in accordance with the following code: GREEN AND YELLOW - EARTH (E) BLUE - NEUTRAL (N) BROWN - LIVE (L) As the colours of the flexible cord of this appliance may not correspond with the coloured markings identifying terminals, proceed as follows: 5 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com · Connect GREEN AND YELLOW coloured cable to terminal marked "E" or Earth Symbol or coloured Green and Yellow. · Connect BROWN cable to terminal marked `L' or coloured Red. Connect BLUE cable to terminal marked "N' or coloured Black. BEFORE USE CAUTION: TO PREVENT INJURY, GET ASSISTANCE WHEN LIFTING OR MOVING THIS COMPRESSOR. Before connecting your compressor to the power supply, check the following: · Set the ON/OFF switch to the OFF position (pushed down). · Make sure that the compressor is on level ground. · Make sure that the supply voltage matches the voltage shown on the data label. CHECK THE OIL LEVEL 1. .Ensure the oil level is filled up to the mark on the sight-glass. 2. If low, top up after unscrewing the filler plug. · Only use ISO100 (SAE30) compressor oil, available from your Machine Mart dealer Part No. 3050796. · Take care not to overfill. 6 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com OPERATION If the compressor has not been used for more then 24 hours, open the drain valve (on the bottom of the reservoir) and drain any condensate which has collected. See page 10. MOVING THE AIR COMPRESSOR · Stop the compressor and disconnect it from the power supply before you move it. · DO NOT lift by (or put strain on) valves or hoses. · Avoid moving the machine if the tank is fully pressurised. ATTACHING AIR TOOLS WARNING: BEFORE CONNECTING AIR TOOLS, MAKE SURE THAT YOU READ THE INSTRUCTIONS SUPPLIED WITH THE TOOL, ALSO ENSURE THAT THE TOOL IS SUITABLE FOR USE WITH THE COMPRESSOR AND HOSE SPECIFICATIONS. 1. Attach the air hose to the outlet valves. 2. Attach the air tool to the other end of the air hose. 3. Turn the outlet valve handle to the on position. NOTE: The outlet valve is shown without the air hose fitted for clarity. NOTE: To adjust the output pressure we recommend that a pressure regulator (not supplied) be fitted between the compressor and the tool. 7 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TURNING THE COMPRESSOR ON 1. Plug the compressor into the power supply. 2. Lift the On/Off button. · The compressor will operate until the reservoir is fully pressurised. It will then shut down. · The compressor will start up again when the pressure in the reservoir decreases. CHECKING THE SAFETY VALVE To make sure that the safety valve works correctly; 1. Unscrew and pull the knurled part of the safety valve. · Air will be released when you pull hard on the valve end and stop when released. 2. If the valve does not operate in this way, do not use the compressor. The compressor must be repaired by a qualified service agent. 3. Once tested, screw the knurled part back. WARNING: DO NOT REMOVE OR TRY TO ADJUST THE SAFETY VALVE. 8 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com REMOVING TOOLS FROM THE AIR HOSE 1. Push down on the On/Off button to stop the compressor. 2. Turn the outlet valve handle to the off position. 3. Operate the tool to depressurise the air hose. 4. Disconnect the tool from the hose. TURNING THE COMPRESSOR OFF 1. Follow steps 1-3 in "Removing Tools from the Air Hose" above. 2. Disconnect the compressor from the power supply. 3. Slowly open the outlet valve to depressurise the reservoir. · You will hear a hissing sound as the reservoir depressurises. 4. Do not leave the compressor unattended if the reservoir is pressurised. 9 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com DRAINING THE RESERVOIR CAUTION: YOU MUST DRAIN THE RESERVOIR AFTER EACH DAYS USE AND BEFORE YOU PUT YOUR COMPRESSOR INTO STORAGE. 1. Turn the compressor off and disconnect from the power supply. 2. Put a container below the drain valve to collect the condensate. 3. Open the drain valve slowly. · Condensation will drain from the reservoir. 4. Close the drain valve when the reservoir has fully drained. USING THE OVERLOAD RESET BUTTON The electric motor is fitted with an automatic overload detector which will stop the motor if an overload is detected. If this happens; 1. SWITCH OFF THE MACHINE (Push the knob down or turn the pressure switch). 2. Allow the compressor to cool down for 5-10 minutes. 3. Press the Reset button shown on the right. 4. Switch on the pressure switch (lift the knob or twist switch). If the overload trips repeatedly it may indicate a fault with the compressor. In this case you should contact the Clarke service department. 10 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com MAINTENANCE WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM THE ELECTRICAL SUPPLY BEFORE CARRYING OUT ANY MAINTENANCE DRAIN THE RESERVOIR After use, always open the drain valve to make sure that any condensate is drained off. CHECKING THE OIL Ensure the oil level is between the min and max marks on the dipstick. See "Check the Oil level" on page 6 and top-up if necessary - (use ISO100 (SAE30) compressor oil, available from your local Machine Mart dealer). CLEANING THE AIR FILTER The air filter must be examined monthly or more often in dusty conditions. 1. Remove the securing bolt with a 7/ 32" hex key and pull the filter from the engine. 2. Remove the filter element and clean the filter using a soft brush. · If necessary, the filter can be carefully cleaned in warm soapy water. · Rinse and let the filter dry completely before refitting. · If the filter or filter element is damaged you must replace it. 3. Reassemble the filter and refit it to the compressor. 11 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com REPLACING THE OIL After the first 100 hours use, replace the oil using (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. CHECKING THE NON-RETURN VALVE If the reservoir pressure decreases for no apparent reason, it is possible that the nonreturn valve is leaking. To check this; 1. Make sure that the reservoir is not under pressure and the compressor is switched OFF. 2. Examine the non-return valve, and replace the gasket and valve if necessary. 12 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com REPLACING THE DRIVE BELT WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM THE ELECTRICAL SUPPLY BEFORE REPLACING THE DRIVE BELT. 1. Rotate the clips on the front of the safety cage. 2. Remove the front of the cage and take out the worn or broken drive belt. 3. Place the new drive belt over the small pulley. 4. Position part of the drive belt over the large pulley as shown. 5. Rotate the large pulley by hand in a clockwise direction whilst guiding the belt on to it. · Take care to avoid trapping your fingers between the pulley and belt. 6. Replace the cage and secure before use. WARNING: NEVER USE THE COMPRESSOR WITH THE GUARD REMOVED. 13 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TROUBLESHOOTING CAUTION: DO NOT TRY TO REPAIR OR ADJUSTMENT IF YOU ARE UNCERTAIN. IF YOU HAVE ANY QUERIES, CONTACT YOUR CLARKE DEALER. PROBLEM PROBABLE CAUSE REMEDY The compressor has stopped and does not start. Bad electrical connections. Overload cutout switch has tripped. 1. Check electrical connections. 2. Clean and tighten if necessary. 1.Switch off and wait approx 5 minutes. 2.Press the reset button and switch on again. Motor windings burnt out. 1. Contact your Machine Mart dealer for a replacement motor. The compressor Compressorheadgasketblown 1.Returnthe machinetoyournearest does not reach the or valve broken. Machine Mart dealer. set pressure and overheats easily. Compressor does The reservoir has already fully 1.Open drain valve to expel air. not start. pressurised. Compressorshouldstartagainwhen pressure reduces. Air leaking from Faulty non-return valve. the non-return valve when the compressor is not running. 1.Drain receiver completely of air. 2.Remove the valve end plug. 3.Carefully clean the valve seat and the gasket 4.Reassemble. Compressorisvery Compressor is damaged and noisy and makes needs overhaul. metallic knocking sound. 1.Return the machine to your nearest Machine Mart dealer. 14 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com COMPONENT PARTS 15 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com COMPONENT PARTS LIST NO DESCRIPTION 1 Screw & Spring Washer 2 Front Cover 3 Front Cover Gasket 4 Ball Bearing 5 Oil Sightglass 6 Breather (M16 x 1.5) 8 Crankcase 7 Baseplate Seal 9 Baseplate 10 Screw & Spring Washer 11 Oil Plug (G1/8") 12 Crankshaft 13 Ball Bearing 14 Bearing Seat Gasket 15 Oil Seal 16 Bearing Seat 17 Spring Washer 18 Hex Screw 19 Flywheel 20 Flat Washer 21 Screw 22 Hex Screw 23 Cylinder Gasket 24 Cylinder 25 Valve Plate Gasket 26 Valve Plate 27 Copper Gasket 28 Valve Reed 29 Head Cover Gasket 30 Connector Nut NO DESCRIPTION 31 Aftercooler 32 Screw & Spring Washer 33 Aftercooler Gasket 34 Screw & Spring Washer 35 Head Cover 36 Air Filter 37 Hex Screw 38 Gudgeon Pin 39 Compression Ring 40 Oil Ring 41 Circlip 42 Piston 43 Connecting Rod 44 Motor Fixing Set 45 Motor 46 Motor Cable 47 Power Cable 48 Safety Valve 49 Pressure Control Switch 50 Pressure Gauge 51 Plug 52 Fixings 53 Non Return Valve 54 Discharge Pipe 55 Hand Valve 56 Hole Plug 57 Reservoir 58 Drain Valve 59 Motor Pulley 60 Key 16 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com NO DESCRIPTION 61 V-Belt 62 Flat Washer 63 Screw 64 Screw & Spring Washer SPECIFICATIONS NO DESCRIPTION 65 Safety Guard 66 Plastic Cowling 67 Bracket 68 Bracket Fixing Parts MODEL Part Number Motor size Voltage Air Displacement Max Pressure Receiver Capacity Ingress Protection Duty cycle Oil requirements Oil capacity Dimensions (L x W x H) Guaranteed Sound Power Level Weight AIRMASTER 18/150 2245310 4HP 230 VAC (50Hz) 504.8L/min (18 CFM) 10 Bar (145psi) 150 L IP20 S3/50% Compressor oil SAE30 0.4L 1260 x 450 x 810 mm 97 dB(A) 97 kg Please note that the details and specifications contained herein, are correct at the time of going to print. We reserve the right to change specifications at any time without prior notice. 17 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com DECLARATION OF CONFORMITY 18 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com DECLARATION OF CONFORMITY 19 Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.comMicrosoft: Print To PDF