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Clarke BOXER 55, Operating & Maintenance Manual

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ROUTINE MAINTENANCE

ROUTINE MAINTENANCE

ROUTINE MAINTENANCE

ROUTINE MAINTENANCE

ROUTINE MAINTENANCE

Replacing the drive belt

Replacing the drive belt

Replacing the drive belt

Replacing the drive belt

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.

2. Place the replacement drive belt

over the small wheel. See 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.

Figure 18

Figure 19

Figure 17

Summary of Contents for BOXER 55

Page 1: ...OPERATION MAINTENANCE INSTRUCTIONS BOXER 55 AIR COMPRESSOR 0408 BOXER 55 AIR COMPRESSOR ...

Page 2: ...nded 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 When disposing of this product When disposing of this product When disposing of this product When disposing of this product When disposing of this product ensure it is disposed of according to all local ordinances ensure it is disp...

Page 3: ...E Safety Precautions 4 Warning Symbols 9 Electrical Connections 10 Parts Identification 11 Assembly 12 Preparation for use 14 Operating instructions 15 Routine Maintenance 19 Troubleshooting 22 Specifications 23 Parts Diagram 24 Parts List 25 Declaration of Conformity 26 ...

Page 4: ...rious injury could Compressed air can be dangerous Death or serious injury could Compressed air can be dangerous Death or serious injury could result from improper or unsafe use of this compressor result from improper or unsafe use of this compressor result from improper or unsafe use of this compressor result from improper or unsafe use of this compressor result from improper or unsafe use of thi...

Page 5: ...WORK AREA CLEAN KEEP THE WORK AREA CLEAN KEEP THE WORK AREA CLEAN KEEP THE WORK AREA CLEAN KEEP THE WORK AREA CLEAN Cluttered areas invite accidents clear the work area of all unnecessary tools debris and furniture DISCONNECT THE AIR COMPRESSOR DISCONNECT THE AIR COMPRESSOR DISCONNECT THE AIR COMPRESSOR DISCONNECT THE AIR COMPRESSOR DISCONNECT THE AIR COMPRESSOR Always disconnect the air compresso...

Page 6: ...TS Never use the air compressor if it has been damaged in any way Have the air compressor repaired by a qualified service engineer Do not use the air compressor if the On Off switch does not operate correctly HANDLE THE AIR COMPRESSOR CAREFULL HANDLE THE AIR COMPRESSOR CAREFULL HANDLE THE AIR COMPRESSOR CAREFULL HANDLE THE AIR COMPRESSOR CAREFULL HANDLE THE AIR COMPRESSOR CAREFULLY Y Y Y Y Operate...

Page 7: ...ng operation the motor connections compressor body cylinder head and tubes may get hot please take care DO NO DO NO DO NO DO NO DO NOT DIRECT THE AIR STREAM A T DIRECT THE AIR STREAM A T DIRECT THE AIR STREAM A T DIRECT THE AIR STREAM A T DIRECT THE AIR STREAM AT THE BODY T THE BODY T THE BODY T THE BODY T THE BODY Do not direct the air stream at people or animals as injury may result Compressed a...

Page 8: ...USE WITHIN THE RECOMMENDED OPERA Y USE WITHIN THE RECOMMENDED OPERA Y USE WITHIN THE RECOMMENDED OPERATING TEMPERA TING TEMPERA TING TEMPERA TING TEMPERA TING TEMPERATURE RANGE TURE RANGE TURE RANGE TURE RANGE TURE RANGE This compressor should only be used in an ambient temperature of between 0O C and 25O C CLEANING AND CONDITION OF THE COMPRESSOR CLEANING AND CONDITION OF THE COMPRESSOR CLEANING ...

Page 9: ...uld 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 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...

Page 10: ...nd 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 letter L or coloured red We recommend that this mac...

Page 11: ...7 7 1 Motor housing 2 On Off switch red button 3 Main reservoir pressure gauge 4 Output pressure regulator 5 Regulator locking ring 6 Output pressure gauge 7 Trolley handle 8 Support foot 9 Drain valve 10 Compressed air reservoir 11 Transportation wheel 12 Data plate 13 Pressure regulator and cut out 14 Oil dipstick 15 Outlet tap 14 14 14 14 14 2 2 2 2 2 4 4 4 4 4 3 3 3 3 3 6 6 6 6 6 5 5 5 5 5 15 ...

Page 12: ...sor from the gauge of fittings assembly Get Get Get Get Get assistance if necessary This unit weighs 57kg assistance if necessary This unit weighs 57kg assistance if necessary This unit weighs 57kg assistance if necessary This unit weighs 57kg assistance if necessary This unit weighs 57kg After removing the compressor from its packaging check the integrity of the unit making sure it has not been d...

Page 13: ...r 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 PREP PREP PREP PREPARING FOR USE ARING FOR USE ARING FOR USE ARING FOR USE ARING FOR USE Before connecting your compressor to the mains supply Check the Oil Check the Oil Check the Oil Check the Oil Check the Oil 1 Check the ...

Page 14: ...tur understood the manufactur understood the manufactur understood the manufactur understood the manufacturers instruction booklet for the tool being used ers instruction booklet for the tool being used ers instruction booklet for the tool being used ers instruction booklet for the tool being used ers instruction booklet for the tool being used Also ensur Also ensur Also ensur Also ensur Also ensu...

Page 15: ...r will restart automatically whenever the pressure in the main tank falls below a certain level 2 Check the operation of the safety valve under pressure daily by pulling the ring as shown in figure 7 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 befor...

Page 16: ...G INSTRUCTIONS TING INSTRUCTIONS P P P P Pressure regulator ressure regulator ressure regulator ressure regulator ressure regulator Regulator locking ring Regulator locking ring Regulator locking ring Regulator locking ring Regulator locking ring lock lock lock lock locked at desired ed at desired ed at desired ed at desired ed at desired pressure pressure pressure pressure pressure Output pressur...

Page 17: ...lace a tool eplace a tool eplace a tool eplace a tool 1 Stop the power supply by pressing down on the on off button red button located on top of the air compressor 2 2 2 2 2 Close the air outlet tap and trigger the equipment spraygun air tool etc Close the air outlet tap and trigger the equipment spraygun air tool etc Close the air outlet tap and trigger the equipment spraygun air tool etc Close t...

Page 18: ...oir before storage voir before 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 When the reservoir pressure gauge indicates zero...

Page 19: ...work ting work ting work Daily Daily Daily Daily Daily Check Oil Check Oil Check Oil Check Oil 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 Drain the tank Drain the tank Drain the tank Drain the tank Drain the tank After use always open the drain valve to ensure t...

Page 20: ... Oil Oil Oil Oil 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 Non R Non R Non R Non R Non Return V eturn V eturn V eturn V eturn Valve alve alve alve alve Examine the non ret...

Page 21: ...e 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 2 Place the replacement drive belt over the small wheel See 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 Figure...

Page 22: ...d oes not sta rt Ba d c onnec tions Overloa d c utout switc h ha s trip p ed or d uty c yc le ha s b een exc eed ed Motor w ind ings b urnt out Chec k elec tric a l c onnec tions Clea n a nd tighten a s nec essa ry Sw itc h off a nd w a it a p p rox 5 m inutes b efore p ressing the reset b utton a nd sw itc hing on a ga in Conta c t your loc a l Cla rke d ea ler for a rep la c em ent m otor The c ...

Page 23: ...n are correct at are correct at are correct at are correct at are correct at the time of going to print the time of going to print the time of going to print the time of going to print the time of going to print However However However However However we reser we reser we reser we reser we reserve the right to change ve the right to change ve the right to change ve the right to change ve the right...

Page 24: ...2 4 PARTS DIAGRAM PARTS DIAGRAM PARTS DIAGRAM PARTS DIAGRAM PARTS DIAGRAM ...

Page 25: ...MOTOR FN540E001604 70 NIPPLE FN011017000 71 SAFETY VALVE FN047206000 72 PRESSURE SWITCH FN321028000 73 PRESSURE REDUCER FN319117000 74 SMALL GAUGE FN330006000 75 NIPPLE FN199110140 76 BIG GUAGE FN330007000 77 MOTOR CABLE FN161CU0007 78 POWER CABLE FN117HA0203 79 SQUARE WASHER FN014005007 80 SCREW FN014013045 81 TAPPING SCREW FN014013042 82 PLASTIC DOWEL FOR BELT GUARD FN020025000 83 BELT GUARD FN1...

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