Clarke RACER 9/50P Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0413

50L BELT DRIVEN AIR COMPRESSOR

MODEL NO: RACER 9/50P

PART NO: 2245000 (230V), 2245003 (110V)

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INTRODUCTION

Thank you for purchasing this CLARKE 50L 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.

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 touch/
remove 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 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.

Wear safety goggles and ear protectors when using this
compressor

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

5

ELECTRICAL CONNECTIONS

RACER 9/50P, 110V

Connect the mains lead to a suitable 110V (50Hz) electrical supply through an
approved plug or a suitably fused isolator switch.

If using a portable 110V transformer, make sure it has a rated capacity sufficient to take
the load of the air compressor.

RACER 9/50P, 230V

Connect the mains lead to a standard, 230 Volt (50Hz) electrical supply through an
approved 13 amp BS 1363 plug, or a suitably fused isolator switch.

If the plug has to be changed because it is not suitable for your socket, or because of
damage, it must be removed and a replacement fitted, following the wiring instructions
shown below. The old plug must be discarded safely, as insertion into a power socket
could cause an electrical hazard

.

If the colours of the wires in the power cable do not agree with the markings on the
plug.

• The BLUE wire must be

connected to the
terminal which is marked
N or coloured black.

•The BROWN wire must be

connected to the
terminal which is marked
L or coloured red.

• The YELLOW AND GREEN

wire must be connected
to the terminal which is

marked E or or
coloured green.

We strongly recommend that this machine is connected to the mains supply through a
Residual Current Device (RCD)

If you are not sure, consult a qualified electrician. DO NOT try to do any repairs.

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

WARNING: THE WIRES IN THE POWER CABLE OF THIS PRODUCT ARE
COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN = EARTH

Plug must be BS1363/A approved.

Always fit

Ensure that the outer sheath of

Neutral

(Blue)

Live

(Brown)

Earth

(Green and

a 13 Amp

the cable is firmly held by the clamp

fuse.

Yellow)

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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 and secure using the
nut supplied.

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

• Take 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 po

wer supply.

3. Slowly open the outlet valve to
depress

urise 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

sup

ply.

2. Put a container below the drain
va

lve 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.

RESET BUTTON

This compressor has a thermal
overload device.

If the motor gets too hot, the thermal
overload device cuts the power
which prevents damage to the motor.

If the thermal overload device
operates, let the motor cool down for
5 minutes and push the reset button.

If you start the compressor and the
overload cutout operates again, stop
the compressor and disconnect from the power supply and have your
compressor examined by a qualified service agent.

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 SAE30
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. Reassemble the filter and refit it to

the compressor using the securing bolt.

WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM
THE ELECTRICAL SUPPLY BEFORE CARRYING OUT ANY MAINTENANCE

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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.

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 through 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 wheel.

4.

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

5. Rotate the large belt wheel by
hand in a clockwise

direction
whilst guiding the belt on to the
wheel.

• Take care to avoid trapping

your fingers between the wheel
and belt.

6. Replace the cage and secure
before use.

NOTE: Never use the compressor with the guard removed.

WARNING: MAKE SURE THAT THE COMPRESSOR IS DISCONNECTED FROM
THE ELECTRICAL SUPPLY BEFORE REPLACING THE DRIVE BELT.

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SPECIFICATIONS

Part Number 2245000 2245003

Max Pressure 10 Bar 10 Bar

Vol ta ge 230 VAC (50Hz) 110 VAC (50Hz)

Air Displacement 9 CFM 9 CFM

Receiver Capacity 50 L 50 L

Fuse Rating 13 A

Dimensions (L x W x H) 870 x 400 x 700 mm 870 x 400 x 700 mm

Guaranteed Sound Power Level 94 dB(A) 94 dB(A)

Weight 48.5 kg 48.5 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.

230V 110V

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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 PAR T NO

001 CRANKCASE

MK

102,MK103

FN4105267

002 CYLINDER MK102XF60 FN4105275

003 HEAD MK102 RP3/8XRP1/4 FN4105259

004 CRANKSHAFT

MK102,MK103

FN4105269

005 LOWER COVER

MK

102,MK103

FN4105257

006 KIT VALVE HOLDER PLATE

MK

102

FN4105292

008 CONROD MK102,MK103 FN4105262

023 KIT INT.FILTER 101X48X67

MK

102

FN4105291

024 AFTERCOOLER MK102 FN4105230

026 END COVER MK102 FN4105254

027 FRONT SUPPORT MK102 FN4105253

029 FLYWHEEL F251.4-A-F19.8

SK

M12

FN4105228

030 BEARING 6205 XL FN9170116

033 DIPSTICK ASSEMBLY MK102 FN4105289

034 GASKE T ANGUS 35 X 25 X 7

D3760

FN9163010

035 SCREW M8X25 8.8 LEFT

(GB5781)

FN4105231

036 WASHER 9.2X36X4 FN4105234

052 COLD START VALVE R1/

4X

2.2BAR

FN4101047

104 HANDLE TIGER

16

8IQ0002

FN9083708

105 NON RET.VAL.1/2"M-1/2"M

LE

FT

FN9048052

106 TAP BALL VALVE R1/4"M

R1

/4"M

FN9047077

107 TAP BALL VALVE 3/8" M FN9047051

108 PRESS.RED.I1/4 O1/4

G1/8

STD R

FN9051116

109 GAUGE 50 1/4 S 0-20

10

BAR

FN9052013

109 GAUGE 40 1/8 S 0-12 FN9052092

110 SAF.VALVE 1/4" CE 10BAR

CH

AOCH

FN9049019

127 RILSAN PIPE 4/6 BLACK FN9270006

131 PRESS.SW.4W 3/8 OL200

ROHS

FN9063084

132 CORD 3X1,5X1850 UK FN9065811

135 MOT.HP2 M80 240/50

5

40C150605

FN4101121

141 SHROUD MK102,MK103 FN4105261

142 BELT GUARD SKM11/13

OB

S9416978

FN4101125

145 SEND.PIPE AL MK102/

50

(B510)

FN4101145

200 PUMP MK102 (1) FN41P0017SGL

300 KIT WHEELS FN41K0197

909 KIT GASKETS MK102

213169001

FN4105851

912 KIT PISTON RING MK102 FN4105287

920 PISTON KIT MK250 FN416025017

(230V)

NO DESCRIPTION PART NO

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PARTS LIST

NO DESCRIPTION PAR T NO

001 CRANKCASE

MK

102,MK103

FN4105267

002 CYLINDER MK102XF60 FN4105275

003 HEAD MK102 RP3/8XRP1/4 FN4105259

004 CRANKSHAFT

MK102,MK103

FN4105269

005 LOWER COVER

MK

102,MK103

FN4105257

006 KIT VALVE HOLDER PLATE

MK

102

FN4105292

008 CONROD MK102,MK103 FN4105262

023 KIT INT.FILTER 101X48X67

MK

102

FN4105291

024 AFTERCOOLER MK102 FN4105230

026 END COVER MK102 FN4105254

027 FRONT SUPPORT MK102 FN4105253

029 FLYWHEEL F251.4-A-F19.8

SK

M12

FN4105228

030 BEARING 6205 XL FN9170116

033 DIPSTICK ASSEMBLY MK102 FN4105289

034 GASKE T ANGUS 35 X 25 X 7

D3760

FN9163010

035 SCREW M8X25 8.8 LEFT

(GB5781)

FN4105231

036 WASHER 9.2X36X4 FN4105234

052 COLD START VALVE R1/

4X

2.2BAR

FN4101047

104 HANDLE TIGER

16

8IQ0002

FN9083708

105 NON RET.VAL.1/2"M-1/2"M

LE

FT

FN9048052

106 TAP BALL VALVE R1/4"M

R1

/4"M

FN9047077

107 TAP BALL VALVE 3/8" M FN9047051

108 PRESS.RED.I1/4 O1/4

G1/8

STD R

FN9051116

109 GAUGE 50 FN9052013

109 GAUGE 40 FN9052092

110 SAFETY VALVE FN9049019

127 RILSAN PIPE 4/6 BLACK FN9270006

131 PRESS.SW.4W 3/8 OL200

ROH

S

FN9063084

132 CAVO ALIM 3X2,5 MK255

1

1560 S/

FN4100183

135 MOT.EL.VEM80 D2M B3

CV

2 11050

FN540C001601

141 SHROUD MK102,MK103 FN4105261

142 BELT GUARD SKM11/13

OB

S9416978

FN4101125

145 SEND.PIPE AL MK102/

50

(B510)

FN4101145

200 PUMP MK102 (1) FN41P0017SGL

300 KIT WHEELS LT50 D150 2RF FN41K0197

909 KIT GASKETS MK102

213169001

FN4105851

912 KIT PISTON RING MK102 FN4105287

920 PISTON KIT MK250 FN416025017

(110V)

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