Clarke RACER 9/100P (3PH), RACER 9/100P Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

LS1013

100L BELT DRIVEN AIR COMPRESSOR

MODEL NO: RACER 9/100P (3PH)

PART NO: 2245025

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INTRODUCTION

Thank you for purchasing this CLARKE 100L Belt Driven Air Compressor.

Read this manual fully before use and follow the instructions carefully. In doing
so you will ensure the safety of yourself and those around you, and you can
look forward to your purchase giving you long and satisfactory service.

Due to our policy of continual product improvement, the images in this
manual may not match the product exactly.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required 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.

PARTS AND SERVICING

For Parts & Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

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SAFETY PRECAUTIONS

Before using your compressor it is in your own interest to read and pay attention
to the following safety rules.

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 to touch
these until the compressor has cooled down.

9. Always set the 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 the 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.

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SAFETY 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 mover 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.

Wear safety goggles and ear protectors when using this
compressor.

This compressor produces a high sound level during
operation. Ear protection should be worn.

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ELECTRICAL CONNECTIONS

The power cable from the main supply must be large enough 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.

Electrical installations should be completed by a qualified electrician.

Electrical connection to the mains supply must be via a suitably fused (see
table below) approved plug or isolator (allowing sufficient capacity for motor
starting). If using a circuit breaker, ensure it is motor rated and of sufficient size
to allow for motor starting.

Compressors should be connected to mains electricity supply via an earth
leakage protection device (RCD).

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.

SUGGESTED FUSE RATINGS

MOTOR SIZE SINGLE PHASE

MOTOR D.O.L.

THREE PHASE MOTORS 415V

KW HP D.O.L. STAR DELTA

0.75 1.0 13 amp 10 amp

1.1 1.5 13/15 amp 10 amp

1.5 2.0 20 amp 10 amp

1.9 2.5 20 amp

2.2 3.0 30 amp 16 amp

3.0 4.0 40 amp 20 amp

4.0 5.5 50 amp 25 amp

5.5 7.5 30 amp

7.5 10.0 25 amp

11.0 15.0 30 amp

15.0 20.0 35 amp

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ASSEMBLY

CAUTION: TO PREVENT INJURY, GET ASSISTANCE WHEN LIFTING THIS
COMPRESSOR.

ATTACH THE WHEELS

1. Slide the axle through the wheel
and hole in the wheel frame.

2. Lock the wheel in place using the
washer and nut provided.

3. Fit the cap into the position
shown.

ATTACH THE SUPPORT FEET

Insert the support feet into the
position shown.

FIT THE HANDLE

4. Loosen the hex bolts and insert
the handle into the brackets as
shown.

5. Tighten the hex bolts.

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BEFORE USE

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. Remove the dipstick from the oil
reservoir.

2.

Ensure the oil level is between the
min and max marks on the
dipstick.

• Only use SAE30 compressor oil,

available from your Clarke
Dealer Part No. 3050801 taking
care not to exceed the
maximum mark.

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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 11

MOVING THE AIR COMPRESSOR

• Stop the compressor and disconnect it from the power supply
before you move it.

• Always use the handle.

• Do not lift by (or put strain on) valves or hoses.

ATTACHING AIR TOOLS

1. Attach the air hose to the outlet
valve.

2. Attach the air tool to the other
e

nd 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.

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.

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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.

CHECK THE SAFETY VALVE

To make sure that the safety valve works correctly.

1.

Pull on the ring attached.

• Air will be released when you
pull on the ring 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.

SET THE OUTLET PRESSURE

1. Use the pressure regulator to set
the outlet pressure.

• Turn clockwise to increase the

pressure.

• Turn counterclockwise to

decrease the pressure.

WARNING: DO NOT REMOVE OR TRY TO ADJUST THE SAFETY VALVE.

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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
th

e 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.

WARNING: ALWAYS SET THE PRESSURE REGULATOR TO ZERO BEFORE YOU
REMOVE OR REPLACE A TOOL.

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DRAINING THE RESERVOIR

1. Turn the compressor off and disconnect from the power supply.

2. Put a container below the drain valve to collect the condensate.

• The drain valve is located on the bottom of the reservoir

3. Open the drain valve slowly.

• Condensation will drain from the reservoir.

4. Close the drain valve when the reservoir has fully drained.

CAUTION: YOU MUST DRAIN THE RESERVOIR AFTER EACH DAYS USE AND
BEFORE YOU PUT YOUR COMPRESSOR INTO STORAGE.

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MAINTENANCE

DRAIN THE RESERVOIR (DAILY)

After use, always open the drain valve to make sure that any condensate is
drained off.

CHECK OIL (DAILY)

Ensure the oil level is between the min and max marks on the dipstick. See
“Check the Oil level” on page 7 and top-up if necessary - (use Clarke SAE 30
compressor oil, available from your local dealer).

CLEAN THE AIR FILTER (MONTHLY)

The air filter must be examined monthly, more often in dusty conditions,

1. Pull the filter cover away from the
compressor

2. Pull out the filter element.

3. Clean the filter using a soft brush.

• If necessary, the filter can be

car

efully 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.

4. Reassembly the filter and replace it o

nto the compressor using the securing

bolt.

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REPLACING THE OIL

After the first 100 hours use, replace
the oil 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.

CHECK THE NON-RETURN VALVE (EVERY 6 MONTHS)

If the reservoir pressure decreases for no apparent reason, it is possible that the
non-return valve is leaking. To check,

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 nece

ssary.

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REPLACING THE DRIVE BELT

1. Rotate the clips shown 90
degrees.

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 pully.

4.

Position part of the drive belt over
the large belt pulley as shown.

5. Rotate the large pulley by hand in
a clockwise direction whilst
guiding the belt on to the large
pulley.

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SPECIFICATIONS

MODEL RACER 9/100P (3PH)

Part Number 2245025

Max Pressure 10 Bar

Vol ta ge 400 VAC (50/60Hz)

Air Displacement 9 CFM

Receiver Capacity 100 L

Dimensions (L x W x H) 1070 x 450 x 770 mm

Guaranteed Sound Power Level 94 dB(A)

Weight 61.5 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.

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TROUBLESHOOTING

CAUTION: DO NOT TRY TO REPAIR OR ADJUST THIS COMPRESSOR IF YOU
ARE UNCERTAIN. IF YOU HAVE ANY QUERIES, CONTACT YOUR DEALER.

PROBLEM PROBABLE CAUSE REMEDY

The compressor
has stoppe

d and

does not start.

Bad electrical connections. 1. Check electrical connections.

2. Clean and tighten if necessary.

Overload cutout switch has
trippe

d.

1. Switch off and wait approx 5
minutes.

2. Press the reset button and
swi

tch on again.

Motor windings burnt out. 1. Contact your Clarke dealer for

a replacemen

t motor.

The compressor
do

es not reach
the set pressure
and overheats
easily.

Compressor head gasket
blown or valve br

oken.

1. Return the machine to your
nearest service agent.

Compressor does
no

t start.

The reservoir has already fully
pressurised.

1. Open drain valve to expel air.
Compressor should start again
when pressure reduces.

Air leaking from
the

non-return
valve when the
compressor is not
running.

Faulty non-return valve. 1. Drain receiver completely of

air

.

2. Remove the valve end plug,

3. Carefully clean the valve seat
an

d the gasket

4. Reassemble.

Air pressure from
the re

gulator will

not adjust.

The diaphragm within the
regulator body is broken.

1. Replace regulator

The compressor is
ver

y noisy and
makes a metallic
knocking sound.

Compressor damaged and
n

eeds overhaul.

1. Return the machine to your
nearest service agent.

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EXPLODED DIAGRAM

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PARTS LIST

NO DESCRIPTION PART NO

1 CRANKCASE FN4105267

2 CYLINDER FN4105275

3 HEAD FN4105259

4 CRANKSHAFT FN4105269

5 LOWER COVER FN4105257

6 KIT VALVE HOLDER FN4105292

8 CONROD FN4105262

23 KIT INT.FILTER FN4105291

24 AFTERCOOLER FN4105230

26 END COVER FN4105254

27 FRONT SUPPORT FN4105253

29 FLYWHEEL FN4105228

30 BEARING FN9170116

33 DIPSTICK ASSEMBLY FN4105289

34 GASKET FN9163010

35 SCREW FN4105231

36 WASHER FN4105234

52 COLD START VALVE FN4101047

141 SHROUD FN4105261

909 GASKET KIT FN4105851

912 PISTON RING KIT FN4105287

920 PISTON KIT FN416025017

104 HANDLE FN9083711

105 NON RETURN VALVE FN9048052

106 TAP B ALL VALVE FN9047077

107 DRAIN VALVE FN9053063

108 PRESSURE REDUCER FN9414364

109 GAUGE 50 FN9052056

110 SAFETYVALVE FN4101065

127 RILSAN PIPE FN9270006

131 PRESS SWITCH +

ST

ARTER

FN9063147

132 CORD FN9065811

135 MOTOR FN845S000

142 BELT GUARD FN4101125

145 SEND PIPE FN4101150

200 PUMP FN41P0017SGL

300 KIT FEET FN41K0174

NO DESCRIPTION PART NO

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

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POPULAR ACCESSORIES

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NOTES

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NOTES