General Operation and Parts Instructions for Gasoline Outfits Compressor MODEL NO. DACE-7161-2 ENGINE HORSE POWER COMPRESSOR BORE COMPRESSOR STROKE AIR TANK CAPACITY APPROXIMATE SCFM SCFM e This product UNLOADER 11liP PRESSURE @ 100 psig @ 175 Psig is not equipped with 1.96/4.3 2.17 30 GAL. 175 PSIG 12.5 12,0 a spark arresting muffler.
TABLE OF CONTENTS Page No. SAFETY PRECAUTIONS ................................................................................... 3-5 GENERAL INFORMATION .................................................................................... 6 COMPRESSOR DIAGRAM ................................................................................... 7 DESCRIPTION OF OPERATION ......................................................................... 6 INSTALLATION ............................................
SAFETY GUIDELINES - DEFINITIONS This manual contains information that is important for you to know and understand. This information relates to protect ing YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use th_ symbols to the right. Please read the manual and pay attention to these sections.
HAZARD RISK WHAT CAN HAPPEN HOW TO PREVENT IT OF BURSTING AIR TANK (cont'd) 3. UNAUTHORIZED MODIFICATIONS TO THE UNLOADER VALVE. SAFETy VALVE. OR ANy WHICH CONTROL TANK THE TANK IS DESIGNED TO WITHSTAND SPECIFIC OPERATING PRESSURES. NEVER MAKE ADJUSTMENTS OR PART(; SUBSTITUTIONS TO ALTER THE FACTORY SET OPERATING 4. EXCESSIVE DO NOT REMOVE THE STIFFENER BAR CONNECTING THE COMPRESSOR PUMP TO THE ENGINE, EXCEPT TO ADJUST BELT TENSION, THEN SECURELY TIGHTEN THE STIFFNER BAR NUTS.
HAZARD WHAT CAN HAPPEN RISK FROM MOVING PARTS i RISK OF BURNS HOW TO PREVENT IT THE ENGINE CAN START ACCIDENTALLY IF THE FLYWHEEL IS TURNED BY HAND OR MOVED BY PULLING ON THE STARTER ROPE. ALWAYS SP PLUG AND BLEED PRESSURE FROM THE TANK BEFORE PERFORMING MAINTENANCE. MOVING PARTS SUCH AS THE PULLEY, FLYWHEEL AND BELT CAN CAUSE IF THEY COME INTO CONTACT WITH YOU OR YOUR CLOTHING. NEVER OPERATE THE_ W_H GUARDS OR COVERS WHICH ARE DAMAGED OR REMOVED.
GENERAL You have pumhaeed a complete compressoroutfit consistingof an air compressor, ASME approved air tank, gasoline engine, and associated controls and instruments. The compressor outfit you have selected is a two stage stationary outfit. Your new compressor can be used for operating paint sprayers, air tools, grease guns, air brushes, caulking guns, and sand blasters, spraying weed killer and insecticides, etc.
Pump Air Intake Gas Engine Oil Dipstick Engine Filter Belt Guard Fuel Tank Two-Stage Pump Engine Air Filter Pump Oil Fill Plug Engine Oil Drain (Not Shown) Throttle Control Pump Oil Sight Glass Oil Drain Plug PressureGauge Drain Valve (Not Shown) Figure I- Typical Gasoline Air Outlet For Discharge Valve Compressor Outfit PAGE 7
INSTALLATION PRE-INSTALLATION INSPECTION NOTE Each air compressor outfit is carefully checked before shipment. With improper handling, damage may result in transit and cause problems in compressor operation; a bent crankshaft, etc. 2. Insertthevibration mountsin the mountingholes. Place a fiat washer under the mounting surface and secure each mount with a Iockwasher and nut. See Figure 3.
NOTE Where a remote air intake is used, enlarge the side of the air intake piping by one pipe size for each t0 feet of length. Stationary outfits must be bolted or lagged to the floor to prevent movement. When lagging down, leave a minimum of 1/8 inch between the bolt and support feet. The use of vibration pads at each support foot is req uired to eliminate the possibility of tank rupture. The flywheel side of the outfitshouldbe placed toward the wall and protected with a totally enclosed belt guard.
FEEDER LINES SLOPEWITH AIR FLOW AIR FLOW \ AIR FLOW _r--_ MAIN DISTRIBUTION AIR LINES SLOPE PIPE IN DIRECTION OF AIR FLOW. WATER CONDENSATE FLOWS ALONG So'PrOM OF PIPE TO DRAIN LEGS, PREVENTING IT FROM ENTERING FEEDER LINES. REGULATOR AIR USAGE LEGS /N LUBRICATOR OF TRAP DRAIN TRAPS FILTER MOISTURE SEPARATOR AND TRAP FLEXIBLE COUPLING AIR DISCHARGE VALVE COCK VALVE VIBRATION Figure 4.
OPERATION Operator Controls The unloader valve for the operation of the gasoline compressor outfit is located between the compressor pump and gasoline engine. The air discharge valve can be located on the end of the air tank. The safety valve and pressure gauge are attached to the tank below the unloader. See page 7. Unloader Valve Pressure loads beyond the design limits may cause tank rupture or explosion.
The unloaderthen reactivates the throttle control and accelerates the engine to fullthrottle. Over-pressurization of the air tank may cause tank rupture or explosion. The air tank is protected from overpressurization by a safety valve. Do not eliminate, make adjustments or substitutions to this device. Occasionally pull the ring on the safety valve to make sure it operates freely. If it doesn't, the safety valve must be replaced. Innercooler safety valves used on two stage outfits must be similarly checked.
3. Periodicallycheck the compressoroutfitduring the first few days of operation to make sure the compressor outfit is runningsmoothly and all controlsare operating properly. NOTE After the compressor has been in operation for 2 to 3 hours, tighten the compressor head bolts. Torque two stage compressor head bolts to 35 foot-pounds using a crisscross pattern when tightening. BREAK-IN PROCEDURES 4. Check the engine fuel tank level.Add fuel if necessary.
c. Check for excessive vibration and noise. Correct any defects found. d. Turn the engine lever or key switchto the OFF position. 2, Check for oil leaks. Correct any leaks found. Close the air dischargevalve. . 4. SHUT DOWN PROCEDURES To stop the engine in an emergency, turn the engine ON/OFF lever or key switch to the OFF position.Under normal conditions,use the following procedures. Remove air tool or accessory. 5. Open outlet valve or regulator to allow air to slowly bleed from the tank.
CLEANING OUTFIT WEEKLY 1. Clean and inspect the compressor air intake filter; replace if necessary. 2. Inspect condition of drive belt; replace if necessary. 3. Clean outside parts of the compressoras well as the engine in order to maintain efficientcooling. The external components of the compressor outfit shouldbe cleaned at least once a week. The air compressor crankcase and head are designed with fins whichallow for propercooling.
CHECKING AND CHANGING AIR INTAKE FILTER Open the drain valve. Continue operating outfituntil all moistureis removedfrom the tank. Closethe drain valvetightly. NOTE Keep the air filter clean at all times. Do not operate compressor outfit when the filters are removed. The conditionof the air intakefiltershouldbe checked once a week. A dirty air intake filter will not allow the compressortooperate at full capacityandwill increase oilusage.
Hold the belt tension untilthe engine mounting hardware can betightened. 4, DRIVE BELT DOWNWARD FORCE 5. Ensure that the belts are centered on the engine pulley and compressorflywheel. NOTE Once the engine has been moved from its factory set location the engine pulley must align to within 1/16 inch to the compressor flywheel. . COMPRESSOR FLYWHEEL Figure 8. Checking Belt Tension Torqueengine mounting boltsto 20 +3 foot pounds. 7. Reinstallthe belt guard. 8. Connect the spark plug wire.
REPLACING DRIVE BELT(cont'd) 6. Reinstall the drive belt. Make sure the belt is centered on the engine pulley and flywheel. 5. 7. Slide the engine back into its originalposition and adjust the belt tension, Figure 8. Slide the engine back intoits originalposition and adjust the belt tension, Figure 8.
6. Reinstall thecheckvalve.DONOTOVERTIGHTEN. Many solvents are highly flammable and a health hazard if inhaled. Always observe the solvent manufacturers safety instructions and warning. SERVICING INTAKE ANDEXHAUST VALVES Theintakeandexhaust valvesas wellasthevalve platesandcylinderheadwill,overaperiodoftime accumulate residue of carbon-like materialon their e. surfaces. The material will decrease the efficiency of the compressor.
TROUBLESHOOTING GUIDE Performing service checks or repairs may expose moving parts, or compressed air sources. Personal injuries may occur. Prior to attempting any service check or repairs, remove the spark plug wire and bleed off all air pressure. Never operate the outfit with the belt guard removed. Repairs should be preformed by an Authorized Service Center personnel only. TROUBLESHOOTING PROBLEM Gasoline Engine will not run.
TROUBLESHOOTING PROBLEM CHART (Continued) CORRECTION CAUSE Clogged fuel line. Clean. Water in fuel. Be sure outfit is adequately protected from the elements so as to preventwater seeping into system. Faulty choke control, Adjust. See engine manufacturer's instructions includedwith engine. Impreper fuel mixture. Use onlyfuel recommendedby engine manufacturer. See manufacturer'sinstructions. Loose ignition system connections. Check all connectionsto insure tightness.
TROUBLESHOOTING PROBLEM Air leaks (cont) Low Discharge Pressure Knocking PAGE 22 CHART (Continued) CAUSE CORRECTION Air leak in safety valve, Operate safety valve manually by pullingon ring. If valve stillleaks, it should be replaced. Defective checkvalve. (Unloader vaive) A defective check valve results in a constant air leak, back through the unloadervalvewhen there is pressure in the air tank and the compressoris notrunning.
TROUBLESHOOTING PROBLEM Knocking(cont'd) Excessive Oil Consumption CHART CAUSE CORRECTION Flywheel loose. Make sureflywheelistightbytightening screw. Torquescrewto 20 +5 -0 foot-pounds. Loose belt. Tighten belt. Restricted air intake. Replace. Compressor overworked. Reduce air consumption or add additional air compressorto take up load. Poor qualityor automotive multiviscosityoil used. CompressorOver heating (Continued) Drain pump and replacewith new oil.
TROUBLESHOOTING PROBLEM Compressor Overheating (Cent) Excessive Belt Wear CHART (Continued) CAUSE CORRECTION Restricted air intake. Remove and clean or replace air filter. Improperlevel and/orgrade of oil used. Check for proper oillevels and recommended oilusage. Damaged valves(intake and/or exhaust). Repair or replace as necessary. Loose belt. Adjust belt tension. Pulley misalignment. Align pulley to within 1/16 inch of the flywheel. Loose pulley. Check for worn key or pulley bore.
COMPRESSOR/PUMP DIAGRAM AND PARTS LIST PAGE 25
Air Compressor Diagram Detail A T_QUE TO 1 _2 F_÷I.B.
Parts List KEY NO.
Compressor Pump Diagram V 2 6 8 10 11 PAGE 28
Parts List KEY NO. PARTS 1 2 3 4 5 ABP-8226501 ABP-5961405 ABP-5940055 ABP-5950057 ABP-5281100 Hardware Kit Head Valve Plate Kit Gasket Kit Filter 6 7 8 9 10 11 12 13 • 14 15 16 • 17 ABP-5981000 ABP-9024011 ABP-9022003 ABP-9013013 ABP-9004009 ABP-9110022 ABP-5000101 ABP-5962020 ABP-8226502 ABP-8227093 ABP-8227092 ABP-8226503 Filter Assy.
ONE YEAR LIMITED FROM WARRANTY DATE OF PURCHASE All merchandise manufactured by DeVllbiss Air Power Company/ExCell Manufacturing is warranted to be free of defects in workmanship and material which occur during the first year from the date of purchase by the original purchaser (initial user). Products covered under this warranty include: air compressors, *air tools, accessories, service parts, pressure washers, and generators used in consumer applications (i.e.
Service Notes PAGE 31
GENERAL OPERATION AND PARTS FOR GASOLINE COMPRESSOR OUTFITS MODEL NO. DACE-7161-2 Call our Toll Free Number 1-800-888-2468, Ext 2, then 1, to obtain the location of the nearest Authorized Service Center for ordering repair parts and for warranty repairs.
