AIR COMPRESSOR operation manual AC5060B ac5060b(p)

CAUTION READ THIS MANUAL CAREFULLY before operating or servicing this air compressor, to familiarize yourself with the proper safety, operation, and standard operating procedures of this unit. FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS MANUAL COULD RESULT IN THE VOIDING OF YOUR WARRANTY, AND PERSONAL INJURY, AND/OR PROPERTY DAMAGE. THE MANUFACTURER OF THIS AIR COMPRESSOR WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL. By following the instructions and recommendations in this manual you will ensure a longer and safer service life of your air compressor.

table of contents

Safety 6  7 

Safety Rules Safety Warnings

Installation & Operation 11 Installation 11 Mounting 11 Wiring 12 Before Operating the Air Compressor 12 Compressor Lubrication 13 Filling the Compressor with Oil 13 Oil Changes 13 Engine Lubrication

Operation 14  Operating Your Air Compressor

Maintenance 15  Maintenance 15  Checking Belt Tension 16  Maintenance Chart

Troubleshooting 17  Troubleshooting Chart

2

introduction

Attention: Read through the complete manual prior to the initial use of your Compressor

Using the Operator’s manual The operating manual is an important part of your Compressor and should be read thoroughly before initial use, and referred to often to make sure adequate safety and service concerns are being addressed. Reading the owner’s manual thoroughly will help avoid any personal injury or damage to your pump. By knowing how best to operate this machine you will be better positioned to show others who may also operate the unit. You can refer back to the manual at any time to help troubleshoot any specific operating functions, so store it with the machine at all times.

3

product identification

Record Identification Numbers Compressor If you need to contact an Authorized Dealer or Customer Service (1-866-850-6662) for information on servicing, always provide the product model and identification numbers. You will need to locate the model and serial number for the pump and record the information in the places provided below. Date of Purchase: Dealer Name: Dealer Phone:

Product Identification Numbers Model Number: Serial Number:

4

safety

Save these Instructions Safety Rules

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION, WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. NOTICE indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death. Hazard Symbols and Meanings

explosion

flying objects

fire

hot surface

toxic fumes

moving parts

read manual

5

safety

warning Serious injury or death may occur from normal sparks in the engine ignition system or engine exhaust/muffler. Injury or death may occur as a result of improper fueling. Serious injury may occur if any air compressor ventilation openings are restricted, causing the air compressor to overheat and start a fire. • Always operate air compressor outdoors in a well ventilated area free of flammable vapors, combustible dust, gases or other combustible materials. • DO NOT SMOKE if spraying flammable material. Locate the air compressor at least 20 feet away from the spray area. (An additional hose may be required.) • Do not smoke while filling engine fuel tank. • Never fill the engine fuel tank while the engine is running or hot. Allow the engine to cool two minutes before refueling. • Do not refuel indoors or in a poorly ventilated area. • Always refuel slowly to avoid the possibility of spilled fuel which may cause a risk of fire. • Do not operate the unit if gasoline is spilled. Wipe the air compressor clean and move it away from the spill. Avoid creating any ignition until the gasoline has evaporated. • Do not store the air compressor near an open flame or any equipment such as a stove, furnace, water heater, etc. which utilizes a pilot light or sparking device. • A spark arrester must be added to the muffler of this engine if it is to be used on any forest covered, brush covered or grass covered unimproved land. The arrester must be maintained in effective working order by the operator. • Never place objects against or on top of air compressor. Operate air compressor at least 12 inches away from any wall or obstruction that would restrict proper ventilation.

6

safety

warning Serious injury or death may occur from an air tank explosion if air tanks are not properly maintained. Serious injury may occur from an air compressor malfunction or exploding accessories if incorrect system components, attachments or accessories are used. Serious injury or death may occur if system safety’s are not properly maintained. Serious injury or death may occur from the battery. • Drain air tank daily or after each use to prevent moisture buildup in the air tank. • If air tank develops a leak, replace the air tank immediately. Never repair, weld or make modifications to the air tank or its attachments. Use only genuine BE repair parts for your air compressor. • Never make adjustments to the factory set pressures. • Never exceed manufacturers maximum allowable pressure rating of attachments. • Because of extreme heat, do not use plastic pipe or lead tin soldered joints for a discharge line. • Never use air compressor to inflate small, low pressure objects such as toys. • Safety Pressure Relief Valves should never be altered, modified, removed or made inoperative. If the device fails, replace immediately with genuine manufacturer replacement part. • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery. • Be certain to disconnect the battery ground terminal before servicing. When disconnecting the cable from the battery, start with the negative terminal, and when connecting them start with the positive cable. • When charting the battery remove the battery vent plugs. • Use only a voltmeter or hydrometer to check battery charge. • DO NOT jump start the battery unless both batteries are of equal voltage and amperage.

7

safety

warning Serious injury or death could occur from inhaling gas engine exhaust which contains carbon monoxide- a poisonous gas that can kill you. You CAN NOT smell or see this gas. Sprayed materials such as paint, paint solvents, paint remover, insecticides, weed killers, etc. contain harmful vapors and poisons. Serious injury or death could occur from inhaling compressed air. The air stream may contain carbon monoxide, toxic vapors or solid particles. • Never us a Gasoline Air Compressor in enclosed or partially-enclosed spaces. Gasoline Air Compressors can produce high levels of carbon monoxide very quickly. When you use a Gasoline Air Compressor, remember that you cannot smell or see carbon monoxide. Even if you can’t smell exhaust fumes, you may still be exposed to carbon monoxide. • If you start to feel sick, dizzy or weak while using this unit, get to fresh air right away. Do not delay. The carbon monoxide from gasoline engine exhaust can rapidly lead to full incapacitation and death. • If you experience serious symptoms, get medical attention immediately. Inform medical staff that carbon monoxide poisoning is suspected. If you experienced symptoms while indoors, have someone call the fire department to determine when it is safe to reenter the effected area. • Operate air compressor only in a well ventilated area. Follow all safety instructions provided with the materials you are spraying. Use of a respirator may be required when working with some materials. • Never inhale air from the air compressor either directly or from a breathing device connected to the air compressor.

warning Serious injury could occur from touching exposed metal parts. These areas can remain hot for some time after the air compressor is shutdown. • Never allow any part of your body or other materials to make contact with any exposed metal parts on the air compressor. • Never allow any part of your body to contact the engine muffler or adjacent areas.

8

safety

warning Soft tissue damage can occur from the compressed air stream. Serious injury can occur from loose debris being propelled at a high speed from the compressed air stream. • Always wear safety glasses to shield the eyes from flying debris. • Never point the air stream at any part of your body, anyone else or animals. • Never leave pressurized air in the air compressor. Shut off air compressor and relieve pressure when storing or attempting maintenance. • Always maintain a safe distance from people and animals while operating the air compressor. • Do not move the air compressor while air tank is under pressure. Do not attempt to move the air compressor by pulling on the hose.

warning Risk of bodily injury from moving parts. • Before performing maintenance, always turn off air compressor. Bleed pressure from the air hose and disconnect spark plug wire to prevent engine from starting unexpectedly. All repairs to the air compressor should be made by an Authorized Service person. • Do not operate without protective covers/guards. Always turn off air compressor before removing any guard. Replace damaged covers/ guards before using the air compressor.

warning Compressed air from the unit may contain hazardous fumes. Air produced by this compressor is not suitable for breathing purposes. Always use a respirator when spraying paint or chemicals, or when sandblasting. Always wear safety glasses or goggles when using compressed air.

9

safety

warning Risk of injury from negligent use. • Never allow children or adolescents to operate this air compressor! • Stay alert-watch what you are doing. Do not operate the air compressor when fatigued or under the influence of alcohol or drugs. • Know how to stop the air compressor. Be thoroughly familiar with controls.

warning Risk of major repair. • Do not operate air compressor without an air filter. • Do not operate air compressor in a corrosive environment. • Always operate the air compressor in a stable, secure position to prevent air compressor from falling. • Follow all maintenance instructions listed in this manual.

warning Air Receiver. • Never weld, drill or change the air receiver in any way. • Over pressurizing the air receiver could cause personal injury or material damage. To protect from over pressurizing, a factory pre-set safety valve is installed. • Any replacement parts should be purchased with the same specifications as the original equipment. Please contact the authorized dealer for replacement parts or specifications.

warning Safety Valve. • Do not remove, make adjustments to or substitute this valve! • This valve is factory installed to prevent over pressurizing of the air receiver. It is factory set at a specific limit for your particular model, and should never be tampered with. • Adjustment by user will automatically void the warranty.

caution The air compressor and motor will get hot while in operation. Never touch the discharge tubing, motor or compressor pump while in operation. The compressor operates automatically while the power is connected and turned on.

10

installation

&

operation

Installation & Operation installation Proper care, maintenance and lubrication ensures longevity. The compressor should always be level for proper lubrication. Use only in a clean, dry, and well-ventilated area. The compressor has heat dissipation fins for proper cooling. Keep the fins and other parts that collect dust clean. Do not place rags or other materials on top of the compressor, as this obstructs cooling and can be a fire hazard. MOUNTING Mount the compressor on a concrete pad or solid floor, making certain that the air receiver feet are level and that no stress is placed on the legs when the mounting nuts, if used, are tightened, shim feet if necessary. Severe vibrations will result when feet are uneven and drawn tightly to the floor, which can lead to welds cracking or fatigue failure of the air receiver.

warning • almost all weld CraCKs or fatigue failures are Caused by improper installation and are not CoVered by warranty. WIRING

warning • regulations reQuire that all wiring be done by a liCensed eleCtriCian, failure to do so Could Void your warranty. A) Single phase models with factory installed wiring between the electric motor and the pressure switch, - do not require a magnetic starter. B) Single phase models which are not pre wired between pressure switch and motor require a magnetic starter or combo switch. C) Three phase models require magnetic starters or combi-pressure switches and are not factory Pre-wired in any way.

NOTICE • Any warranty claims for electrical components can only be considered when submitted with proof of proper electrical installation.

11

installation

&

operation

WARNING • all wiring information is stated on the eleCtriC motor and on the pressure switCh or proVided with the magnetiC starter, if supplied. WII CustomER serViCe personnel Cannot, by law, proVide any wiring information. BEFORE OPERATING THE AIR COMPRESSOR Please check the following carefully: 1) Check to see that nuts and bolts are all snug. 2) Check if the quantity and quality of oil is correct. 3) If the intake filters are dirty, they should be replaced or cleaned. COMPRESSOR LUBRICATION

WARNING • always CheCK the oil leVel and Quality before start–up. do not add or Change oil while the unit is running. use only reCommended non-detergent oil. RECOMMENDED OIL eagle compressor oil

#EAOIL 10 (1 Litre)

eagle compressor oil

#EAOIL 40 (4 Litres)

* Compressor originally filled with SAE 20W oil (ISO 68) Eagle compressor oil is a non-detergent mineral oil formulated with additives to help minimize carbon build-up, increase ring life and reduce oil consumption, for use at ambient temperatures of 0° to 30°C (32°F 86°F). Regular mineral oils can also be used in the compressor. Always use a non-detergent oil with the following specifications: OTHER APPROVED OILS ambient temperatures at point of operation

sae VisCosity iso VisCosity

-16°C TO 0°C (3.2°F - 32°F)

SAE 10W

1°C TO 26°C (33.8°F - 78.8°F)

SAE 20W

ISO 68

ABOVE 27°C (80.6°F)

SAE 30W

ISO 100

12

ISO 32

installation

&

operation

FILLING THE COMPRESSOR WITH OIL 1) Remove the oil filler plug 2) Slowly pour the proper oil into the pump crankcase. 3) Always keep oil level in the middle of the sight glass. OIL CHANGES

NOTICE • Initial oil change due at 100 hours. • Change oil every 300 hours or 3 months; whichever comes first. 1) Remove the oil drain plug. Allow oil to drain completely. 2) Replace the oil drain plug. 3) Refill with the recommended oil to the proper level. ENGINE LUBRICATION (if engine driven) Check engine Owner’s manual for lubrication and maintenance requirements.

13

operation

Operation OPERATING YOUR AIR COMPRESSOR

WARNING • EXTRA CARE SHOULD BE TAKEN TO AVOID PERSONAL INJURIES WITH AUTOMATIC CONTROLLED COMPRESSORS. 1) Check unit for any damage. All compressors are tested and inspected at the factory and supplied in perfect condition. Any damage is the freight carriers’ responsibility and you must notify the freight company immediately upon discovering any damage, and submit a claim. Ensure you have documented the damage on the waybill receipt if possible. 2) Check compressor installation and wiring 3) Turn on electric power and turn pressure switch knob to “auto”. Compressor should start running and air pressure should build up in the air receiver as evidenced by the air receiver pressure gauge. Make sure drain valve and outlet valve are closed. 4) When air receiver pressure reaches the pressure switch cut-out pressure, the compressor should stop automatically and you are now ready to start using the compressed air. As air is used, the pressure in the air receiver will drop and cause the pressure switch to close and this will automatically start the compressor. 5) The compressor will cycle automatically until you are finished using compressed air and the pressure switch knob is switched to “off”.

WARNING • DO NOT LEAVE THE POWER TO THE COMPRESSOR OVERNIGHT OR CONNECTED WHEN UNIT IS UNATTENDED.

14

8

maintenance

Maintenance maintenance

installation&operation Before doing any maintenance or adjustments to your air compressor, the following safety precautions should be taken:

1) Turn off and lock out electric power. maintenanCe

2) Drain air receiveror and air lines oftoair pressure. Before doing any maintenance adjustments your air compressor, the following safety precautions should be taken: ► ►

checking belt tension (if belt driven)

TURN OFF AND LOCK OUT ELECTRIC POWER.

AdjustAIR belt(s) so when pressure is applied the center, there is DRAIN RECEIVER AND AIR LINES OF AIRatPRESSURE. approximately 1/2” slack (see diagram below).

If the belt is installed too tight, thedriven) motor might be overloaded. This CheCKingbelttension(if belt

will cause the motor to overheat. If the belt is installed too loosely, it will

Adjust belt(s) so when pressure is applied at the center, there is approxislip and excessive wear and vibration will occur. mately 1/2” slack (see diagram “Figure A” below). If the belt is installed too tight, the motor might be overloaded. This will cause the motor to overheat. If the belt is installed too loosely, it will slip and excessive wear and vibration will occur.

1) 2) ) 4) 5) 6) ) 8) 9)

figurea

Centredistance

tootight

slightbow Correcttension

tooloose

howtoinstallanewbeltifreQuired: How to install a new belt if required: 1) Disconnect power supply. Disconnect power supply. 2) Remove belt guard. Remove belt guard. 3) Loosen motor bolts and slide motor toward compressor head just Loosen motor bolts and slide compressor head just enough to allow old motor belt totoward be removed. enough to allowproper old belt to be removed. 4) Install replacement belt. 5) proper Slide replacement motor away belt. from compressor head to provide recommended Install tension shown in diagram (Figure A.) recommendSlide motor awayasfrom compressor head to provide 6) Align using a straight edgeA.)ruler against pulley’s edge. ed tension as belt shown in diagram (Figure 7) Fasten motor bolts. Align belt using a straight edge ruler against pulley’s edge. 8) Ensure motor and compressor pulley’s are secure. Re-check Fasten motor bolts. alignment. 9) motor Re-install belt guard and reconnect power supply. Ensure and compressor pulley’s are secure. Re-check alignment. 10) Belt tension should be checked after 20 hours of operation. Check tension monthly thereafter.power supply. Re-install belt guard and reconnect

10) Belt tension should be checked after 20 hours of operation. Check tension monthly thereafter.

15

maintenance

MAINTENANCE CHART MAINTENANCE CHART PROCEDURE

DAILY

Check oil level

X

Drain condensation from air receiver

X

Check for unusual noise/vibration

X

Tighten nuts and bolts

X

WEEKLY

Clean dust and foreign matter

X

Clean air filter

X

Replace worn filters

X

Check V-belts for wear

X

MONTHLY

Inspect unit for leaks

X

Tighten joints if leaks found

X

Check V-belts for tension

X

Check pulley and motor sheave for alignment

X

QUARTERLY /300 HRS

Inspect for corrosion/damage

X

Change compressor oil

X

Replace filter

X

16

troubleshooting

Troubleshooting TROUBLESHOOTING CHART PROBLEM

PROBABLE CAUSE

CORRECTIVE ACTION

Will not start.

Incorrect power supply and/ or wiring.

Make sure power is turned on. (Consult with a licensed electrician).

Air receiver is at full pressure.

Drain air receiver.

Safety valve leaks.

Replace safety valve.

Drain cock open.

Close drain cock.

Loose tubes or fittings.

Tighten fittings.

Dirty or plugged air filter.

Clean or replace as necessary.

Defective unloader valve.

Replace unloader valve.

Too much oil in the crankcase.

Drain oil and fill to proper level.

Improper oil viscosity.

Drain and replace oil

Compressor overheated.

Air pressure regulated too high.

Restricted air filter.

Clean or replace air filter.

Worn piston rings.

Replace piston rings.

Dirty compressor head, cylinder or intercooler.

Clean with compressed air.

Clogged inlet filter.

Clean or replace as necessary.

Operating pressure too high.

Reduce operating pressure.

Low oil or wrong oil being used.

Drain and replace oil.

Compressor cycle too long. Proper cycle is 50-60% on Stop/Start operation.

Allow for longer rest between cycles.

Leaks in air system.

Check for leaks.

Pressure switch differential adjusted too close.

Replace worn components as necessary. Make necessary adjustments.

Defective compressor valves.

Replace valves.

Compressor too small for intended use.

Upgrade to larger compressor.

Low pressure

Oil in discharge

Compressor overheats

Compressor loads & unloads or stops & starts excessively

17

troubleshooting

PROBLEM

PROBABLE CAUSE

CORRECTIVE ACTION

Insufficient output, low discharge pressure

Clogged inlet filter.

Clean or replace as necessary.

Leaks in air lines, air valves, fittings, etc...

Replace worn components as necessary.

Drive belts slipping.

Tension V-belts.

Drain valve left open.

Close drain valve.

Defective pressure gauge.

Replace pressure gauge.

Leaking head gasket.

Replace head gasket.

Dirty or plugged inter cooler tubes.

Remove and clean inter cooler tubes.

Pressure switch adjusted too low, or defective.

Make necessary adjustments.

Worn or defective compressor valves.

Replace valves.

Worn piston, worn out rings.

Replace worn parts.

Faulty check valve.

Replace check valve.

Valves incorrectly installed

Install valves correctly.

Drive belts too tight.

Tension V-belts.

Defective pressure switch.

Replace switch.

Defective Motor.

Replace Motor. (Consult licensed electrician).

Power being supplied by generator.

Consult licensed electrician

Cycle too short; compressor does not operate long enough to vaporize condensed moisture during compression.

Allow for longer operating cycle.

System pressure leaking back through check valve when compressor is stopped.

Check and replace check valve if necessary.

Wrong oil being used.

Drain and replace with proper oil

Motor stalls or blows breaker

Water in crankcase oil gets dirty, rusty valves or cylinders

18

troubleshooting

PROBLEM

PROBABLE CAUSE

CORRECTIVE ACTION

Excessive vibration / compressor knocks

Loose compressor, motor or engine guard.

Tighten components.

Compressor not level.

Level compressor

Feet bolts over tightened to floor.

Loosen feet bolts.

Excessive discharge pressure.

Reduce operating pressure.

Wrong oil being used.

Drain and replace with proper oil.

Loose flywheel, drive, pulley or drive belts.

Tighten loose components and check belts.

Worn connector rods, wrist pin or main bearings.

Check and replace worn parts.

Compressor valves loose or broken.

Check and replace worn or broken valves..

Check valve knocks at low pressure.

Remove and clean check valve.

Clogged inlet filter.

Replace check valve.

Wrong oil being used, wrong viscosity.

Clean inlet filter or replace as necessary.

Oil level too high.

Fill compressor with oil to proper level.

Crankcase breather valve malfunction.

Replace crankcase breather.

Compressor runs unloaded too long

Increase load or stop compressor when not needed. Check for air leaks.

Compressor operating outside in cold conditions or inlet filter not protected against weather.

Provide adequate protection against extreme weather conditions.

Worn piston rings.

Replace piston rings.

Piston rings not seated.

Allow 100 hours of normal operation for new rings to seat. Drain oil and refill with Eagle EAOIL oil or other approved oil.

Compressor uses too much oil

19

If you need assistance with the assembly or operation of your Compressor please call

1-866-850-6662 20