BOXER 55 AIR COMPRESSOR OPERATION & MAINTENANCE INSTRUCTIONS 0408 ©
Thank you for purchasing this Clarke Boxer 55 Air Compressor which is fitted with a 50 litre air reservoir. Please read this leaflet thoroughly and carefully follow all instructions. In doing so you will ensure the safety of yourself and that of others around you, and you can look forward to the compressor giving you long and satisfactory service. GUARANTEE This product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase.
CONTENTS PAGE Safety Precautions ......................................................................... 4 Warning Symbols ............................................................................ 9 Electrical Connections .................................................................. 10 Parts Identification ......................................................................... 11 Assembly .........................................................................................
SAFETY PRECAUTIONS WARNING As with all machiner y, there are cer tain hazards involved with their certain operation and use. Exercising respect and caution will considerably lessen the risk of personal injur y. However However,, if normal safety precautions are overlooked, or ignored, personal injury to the operator ty may result.
SAFETY PRECAUTIONS TRAINING: Prior to use all operators should become familiar with the instructions in this booklet. In particular, become familiar with the ON/OFF control for emergency stopping. AL WA YS USE EYE PRO TECTION ALWA WAYS PROTECTION TECTION:: When operating the air compressor, always use eye protection, and make sure that other people in the work area are also using eye protection. Eye protectors must provide protection from flying particles both from the front and from the side.
SAFETY PRECAUTIONS ST ORE THE AIR COMPRESSOR PROPERL Y: When not in use the air compressor STORE PROPERLY should be stored in a secure, dry place out of the reach of children. Always lock up the storage area. PROTECT YOUR HEARING: Ear protection should be worn when operating this compressor. MAINTAIN THE AIR COMPRESSOR WITH CARE: If the air compressor is damaged in any way, have it repaired by a qualified service engineer.
SAFETY PRECAUTIONS ADEQUATE VENTILATION: The compressor should only be used in areas with adequate ventilation and should not be exposed to heat, or used near inflammable substances. NEVER USE AN AIR COMPRESSOR WHICH APPEARS DEFECTIVE OR IS OPERA TING ABNORMALL Y: If the compressor operates unusually or makes strange ABNORMALLY OPERATING noises, switch off immediately and purge the air tank. Arrange repair with an authorised service centre.
SAFETY PRECAUTIONS NEVER OPERATE WITHOUT ALL GUARDS IN PLACE: Never operate without all guards or safety features in place and in proper working order. NEVER OPERATE IN THE PRESENCE OF FLAMMABLE LIQUIDS OR GASES: The air compressor produces sparks during operation. CHECK FOR DAMAGED PPARTS ARTS AND AIR LEAKS LEAKS:: If any part of the compressor is damaged, it should be carefully checked to determine that it will operate correctly and perform its intended function.
WARNING SYMBOLS READ THIS INSTRUCTION BOOKLET CAREFULLY BEFORE POSITIONING, OPERATING OR 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. Risk of accidental start-up. The compressor could start automatically in the event 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.
ELECTRICAL CONNECTIONS Connect the mains lead to a 230 Volt (50Hz) single phase 30 amp electrical supply, through a suitably fused isolator with a fuse rating of 20 Amps. DO NOT connect to a domestic system via a 13 AMP plug.
PARTS IDENTIFICA TION IDENTIFICATION 2 4 5 3 15 14 6 13 1 7 12 10 11 9 8 1 Motor housing 9 2 On/Off switch (red button) 10 Compressed air reservoir 3 Main reservoir pressure gauge 11 Transportation wheel 4 Output pressure regulator 12 Data plate 5 Regulator locking ring 13 Pressure regulator and cut-out 6 Output pressure gauge 14 Oil dipstick 7 Trolley handle 15 Outlet tap 8 Support foot 11 Drain valve
A SSEMBL Y SSEMBLY W ARNING! Befor e assembling and using the air compr essor e sur e that you have Before compressor essor,, mak make sure read and understood all of the safety instructions. Installation Take care when lifting the compressor from the packaging. CAUTION! Do not lift the compressor from the gauge of fittings assembly assembly.. Get assistance if necessary. This unit weighs 57kg.
A SSEMBL Y SSEMBLY Moving the air compressor Before moving the compressor, switch off and disconnect it from the mains power supply. • Always use the handle. • Do not lift by (or put strain on) fittings, valves or hoses. • Take care when moving the compressor to avoid damaging the valves or fittings. The compressor is heavy, take care when lifting and moving this compressor to avoid personal injury. Get assistance if necessary.
PREP ARING FOR USE PREPARING Before connecting your compressor to the mains supply, check the following:• The mains voltage is 230V. • The ON/OFF switch is in the OFF (lower) position. • The pressure regulator should be set at its lowest setting, i.e. turned fully anticlockwise. • If the compressor has not been used for 24 hours or so, open the drain valve to drain any condensate which may have accumulated. When clear, close the drain valve, finger tight.
OPERA TING INSTRUCTIONS OPERATING Switching the air compressor ON The compressor will mak e a continuous loud noise when the tank is charging make this is normal normal.. 1 Lift the red On/Off switch located on top of the pressure regulator to switch the compressor ON. • The compressor will then charge the main tank to 10 bar (145 psi). When this pressure is reached, the compressor will switch off.
OPERA TING INSTRUCTIONS OPERATING 5 The illustration below shows the pressure regulator locked at 6 bar . • Never set the pressure higher than the rated pressure of the attachments being used, as there is a risk of bursting and resultant injury. To increase the output pressure from this value you will need to loosen the locking ring. • Only alter this setting if you are using an air tool which is capable of supporting the higher pressure. 6 Open the outlet tap.
OPERA TING INSTRUCTIONS OPERATING Switching the air compressor OFF To switch the air compressor off, 1. Close the outlet tap and press down on the on/off button (red button) located on top of the air compressor. 2. Switch off the mains supply and remove the plug. • You should never leave the compressor air reservoir unattended while under pressure. • Always release the pressure from the reservoir when not in use or prior to storage, as described in 'Draining the reservoir' on page 18.
OPERA TING INSTRUCTIONS OPERATING Draining the reser voir reservoir CAUTION! It is important to drain the reser voir before storage reservoir storage.. 1 Press the red On/Off button down to switch the air compressor off and remove the plug from the mains supply. • Place a suitable container beneath the compressor to catch any condensate. 2 Carefully undo the drain valve anticlockwise until you hear a hissing noise, this is the reservoir depressurising. See figure 11.
ROUTINE MAINTENANCE IMPOR e carr ying out any maintenance, always disconnect the IMPORTTANT ANT:: Befor Before carrying compr essor fr om the mains supply eceiver and, if necessar necessaryy, compressor from supply,, drain the air rreceiver allow the machine to cool down befor e star ting work. before starting Daily Check Oil Ensure the oil level is between the min and max marks on the dipstick. See page 12 and top-up if necessary - (use Clarke SAE 40compressor oil, available from your local dealer).
ROUTINE MAINTENANCE Every six months Make sure that all bolts are securely tightened. Clean all the external parts of the compressor. Oil After the first 100 hours use, replace the oil completely using Clarke SAE40 compressor oil. Thereafter, replace the oil completely 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.
ROUTINE MAINTENANCE Replacing the drive belt 1 Rotate the clips on the front of the safety cage. Remove the front of the cage and take out the worn or broken drive belt. Figure 17 2. Place the replacement drive belt over the small wheel. See figure 18. Figure 18 3. Position part of the drive belt over the large belt wheel as shown in figure 19. 4. Rotate the large belt wheel by hand in a anticlockwise direction whilst guiding the belt on to the belt wheel.
TROUBLE SHOOTING With considerate use, your Clarke Boxer 55 Air Compressor should provide you with long and trouble free service. Routine checks should be made on both the electrical supply as well as on all the compressed air lines and connections. If any fault appears, the reason for which is not immediately obvious, we recommend that you contact your local Clarke dealer. Fa ult Ca use Re m e dy Ba d c o nne c tio ns. The c o m p re sso r sto p p e d a nd d o e s no t sta rt.
SPECIFICA TIONS SPECIFICATIONS Electrical Supply ..................................... 230 V, 1 Phase 50Hz Max. Operating Pressure ....................... 10 bar / 145 psi Motor Rating ........................................... 3 HP Air Displacement ................................... 12.2 cuft/min Air Receiver ............................................ 50 litre Net Weight .............................................. 57kg Dimensions ( L x W x H ) .........................
PARTS DIAGRAM 24
PARTS LIST NO. DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 50 51 52 53 54 55 56 57 58 PART NO NO.. NO.
