GENERAL MANUAL FOR Oil-Lubricated Single Stage Electric Motor Powered Air Compressor CAUTION COMPRESSOR OIL MUST BE ADDED BEFORE USE.
TABLE OF CONTENTS SAFETY GUIDELINES ........................................... 2 LIMITED WARRANTY ........................................... 3 Before Starting ..................................................... At Start-Up ........................................................... Shutting Down ..................................................... 12 12 12 MAINTENANCE ..................................................... Routine Maintenance Schedule ........................... Before Each Use ...
LIMITED WARRANTY ONE YEAR FROM DATE OF PURCHASE All merchandise manufactured by DeVilbiss 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., personal residential household usage only).
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT. HAZARD RISK OF EXPLOSION OR FIRE WHAT CAN HAPPEN HOW TO PREVENT IT IT IS NORMAL FOR ELECTRICAL CONTACTS WITHIN THE MOTOR AND PRESSURE SWITCH TO SPARK.
HAZARD RISK FROM FLYING OBJECTS WHAT CAN HAPPEN HOW TO PREVENT IT THE COMPRESSED AIR STREAM CAN CAUSE SOFT TISSUE DAMAGE TO EXPOSED SKIN AND CAN PROPEL DIRT, CHIPS, LOOSE PARTICLES AND SMALL OBJECTS AT HIGH SPEED, RESULTING IN PROPERTY DAMAGE OR PERSONAL INJURY. ALWAYS WEAR ANSI Z87.1 APPROVED SAFETY GLASSES WITH SIDE SHIELDS WHEN USING THE COMPRESSOR. NEVER POINT ANY NOZZLE OR SPRAYER TOWARD ANY PART OF THE BODY OR AT OTHER PEOPLE OR ANIMALS.
HAZARD RISK FROM MOVING PARTS WHAT CAN HAPPEN 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 DISCONNECT THE SPARK PLUG AND BLEED PRESSURE FROM THE TANK BEFORE PERFORMING MAINTENANCE. MOVING PARTS SUCH AS THE PULLEY, FLYWHEEL AND BELT CAN CAUSE SERIOUS INJURY IF THEY COME INTO CONTACT WITH YOU OR YOUR CLOTHING. NEVER OPERATE THE COMPRESSOR WITH GUARDS OR COVERS WHICH ARE DAMAGED OR REMOVED.
GENERAL INFORMATION An air line filter is usually required for removal of moisture and oil vapor in compressed air when a paint spray gun is used. An in-line lubricator is usually required for air tools to prolong tool life. Separate air filters which combine the functions of air regulation and/or moisture and dirt removal should be used where applicable.
DESCRIPTION OF OPERATION (cont'd) valve will exhaust the compressed air to the atmosphere (blow-off). When the tank pressure drops to a pre-determined point, the unloader valve closes and causes the tank pressure to increase. Safety Valve: If the pressure switch does not shut off the air compressor at its cut-out pressure setting, the safety valve will protect against excessive high pressure by “popping out” at its factory set pressure (slightly higher than the pressure switch cut-out setting).
ASSEMBLY INSTRUCTIONS Items Needed for Assembly 4. Install cotter pins into the holes in the axle holding cups, then use a pair of pliers to bend the cotter pin ends to retain the axle in the axle holding cups. 5. Using a 1/2” socket or open-end wrench, remove the bolts holding the unit to the wooden shipping skid, then lift the unit by the handles and wheel it off the skid. 6.
GROUNDING INSTRUCTIONS (cont'd) Certain air compressors can be converted from 120V to 240V operation. When converting an air compressor to 240V operation, the attached three-prong 120V cord assembly must be replaced with a three-pronged 240V cord assembly that can be purchased through an Authorized Warranty Service Center. To locate an Authorized Warranty Service Center nearest you, call us at 1-800-888-2468, Ext. 2 then 1. IMPROPER GROUNDING CAN RESULT IN ELECTRICAL SHOCK.
PREPARATION FOR USE (cont'd) 3. Replace the pump oil fill plug and tighten. 1. Place air compressor on a level surface. 2. Remove the pump oil fill plug and slowly add compressor oil to the crankcase of the pump until it is even with the top of the oil fill hole (no lower than 3/8” from the top at any time). Fill with oil slowly. If oil is added too quickly, it will overflow and appear to be full. NOTE Drain and refill the pump crankcase after the first 100 hours of operation.
OPERATING PROCEDURES before attaching, then adjust the pressure regulator gauge for that value. Daily Start-Up Checklist Before Starting Perform the following checks before starting the air compressor. 1. Make sure that nothing is blocking the belt guard, air openings, or air filter inlet. 2. Pull the ring on all safety valves to make sure the valves move freely and smoothly. 3. Check the oil level in the pump and add oil if necessary. 4.
MAINTENANCE 4. Inspect for oil leaks and repair any leaks found. 5. Inspect air filter, replace if necessary. Every 40 Hours of Operation: 1. Clean and inspect the air intake filter; replace if necesssary. 2. Inspect condition of drive belt; replace if necessary. Every 100 Hours of Operation: 1. Drain and refill compressor crankcase with 16 fluid ounces (473.2 ml) of clean compressor oil or Castrol Heavy Duty 30 weight oil. 2.
SERVICE INSTRUCTIONS (cont'd) Belt – Replacement Use the following procedure to inspect, clean or replace the check valve. 1. Unplug compressor from power source and release air pressure from the air tank. 2. Loosen the top and bottom compressor outlet tube nuts and remove the outlet tube. 3. Unscrew the check valve (turn counterclockwise) using a 7/8" socket or open end wrench. 4.
SERVICE INSTRUCTIONS (cont'd) 5. If belt tension is not correct, readjust as in step 2 of this procedure. 6. When proper belt tension is achieved, tighten the remaining motor mounting bolts. Pressure Switch - Replacement PRESSURE LOADS BEYOND DESIGN LIMITS MAY CAUSE AIR TANK RUPTURE OR EXPLOSION. PRESSURE SWITCH OPERATION IS RELATED TO MOTOR HP, AIR TANK RATING AND SAFETY VALVE SETTING.
NOTE Do not use gasket cement on any gasket surface as this may clog compressor valve cavities and air flow areas. MANY SOLVENTS ARE HIGHLY FLAMMABLE AND A HEALTH HAZARD IF INHALED. ALWAYS OBSERVE THE SOLVENT MANUFACTURER'S SAFETY INSTRUCTIONS AND WARNINGS. 6. Reinstall valve plate and use new gaskets. 7. Install the cylinder head. Snug mounting screws and studs tight, then torque to 25 to 30 ft.-lbs. starting at the center and working toward the outside. 8.
TROUBLESHOOTING GUIDE PERFORMING REPAIRS MAY EXPOSE VOLTAGE SOURCES, MOVING PARTS OR COMPRESSED AIR SOURCES. PERSONAL INJURY MAY OCCUR. PRIOR TO ATTEMPTING ANY REPAIRS, UNPLUG THE COMPRESSOR AND BLEED OFF ALL TANK AIR PRESSURE. PROBLEM Excessive tank pressure - safety valve pops off. CAUSE Pressure switch does not shut off motor when air compressor reaches “cut-out” pressure. CORRECTION Move the pressure switch "OFF/ONAUTO" lever to the “OFF” position.
TROUBLESHOOTING GUIDE (cont'd) PROBLEM Knocking noise (cont'd) CAUSE Loose belt or belt too tight. Carbon build-up. Motor will not run. Motor overload protection switch has tripped. Possible defective capacitor. Possible defective motor. Tank pressure exceeds pressure switch "cut-in" pressure. Check valve stuck open - fails to relieve head pressure; motor cannot start. Loose electrical connections. Pressure release valve on pressure switch has not unloaded head pressure.
TROUBLESHOOTING GUIDE (cont'd) PROBLEM Restricted air intake. Air compressor is not supplying enough air to operate accessories. CAUSE Dirty air filter. Prolonged excessive use of air. Air compressor is not large enough for air requirement. Restricted air intake filter. Loose belt. Hole in hose. Check valve restricted. Air leaks. Excessive belt wear. Belt is too loose or tight. Loose pulley. Pulley misalignment. Squealing sound. Loose belt. There is no oil in the pump. CORRECTION Replace filter.
GENERAL MANUAL FOR Oil-Lubricated Single Stage Electric Motor Powered Air Compressor 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. 24 hours a day, 7 days a week.
