DeVilbiss DACE-7161-2 User Manual
General Operation and
Parts Instructions for
Gasoline Compressor
Outfits
MODEL NO.
DACE-7161-2
ENGINE HORSE POWER 11HP
COMPRESSOR BORE 1.96/4.3
COMPRESSOR STROKE 2.17
AIR TANK CAPACITY 30 GAL.
APPROXIMATE UNLOADER PRESSURE 175 PSIG
SCFM @ 100 psig 12.5
SCFM @ 175 Psig 12.0
•
This product is not equipped with a spark arresting muffler. If the product will be used around
flammable materials, or on land covered with materials such as agricultural crops, forest, brush, grass, or other similar
items, then an approved spark arrester must be installed and is legally required in the state of California. It is a
violation of California statutes section 130050 and/or sections 4442 and 4443 of the California Public Resources
Code, unless the engine is equipped with a spark arrestor, as defined in section 4442, and maintained in effective
working order. Spark arresters are also required on some U. S. Forest service land and may also be legally required
under other statutes and ordinances.
•
Engine exhaust from this product contains chemicals known, in certain quantities, to cause cancer, birth defects or
other reproductive harm.
MGP-DAC-7161-2A 7/9/99
213 Industrial Dr. • Jackson, TN 38301
TABLE OF CONTENTS
Page No.
SAFETY PRECAUTIONS ................................................................................... 3-5
GENERAL INFORMATION .................................................................................... 6
COMPRESSOR DIAGRAM ................................................................................... 7
DESCRIPTION OF OPERATION ......................................................................... 6
INSTALLATION ................................................................................................ 8-10
Pre-Installation Inspection ................................................................................ 8
Vibration Mounting Kit (Stationary Compressor Outfits) .................................... 8
Location of the Compressor Outfit ................................................................ 8-9
Air Line Piping (Stationary Compressor Outfits) ........................................... 9-10
OPERATION ................................................................................................... 11-14
Operator Controls ..................................................................................... 11-12
Daily Startup Procedures .......................................................................... 13-14
Break-In Procedures ....................................................................................... 13
MAINTENANCE ............................................................................................. 14-17
Routine Maintenance Schedule ......................................................................14
Cleaning the Air Compressor Outfit .................................................................15
Checking and Changing Oil ............................................................................ 15
Checking and Changing Air Intake Filter ..........................................................16
Draining Water from Air Tank...........................................................................16
Checking and Adjusting Belt Tension .............................................................. 17
SERVICE INSTRUCTIONS ............................................................................ 17-19
Replacing Drive Belt ................................................................................. 17-18
Engine Pulley and Flywheel Alignment ............................................................18
Check Valve Inspection and Cleaning ....................................................... 18-19
Servicing Intake and Exhaust Valves .............................................................. 19
TROUBLESHOOTING GUIDE ....................................................................... 20-24
Air Compressor Diagram & Parts List ........................................................ 26-27
Compressor Pump Diagram & Parts List ................................................... 28-29
WARRANTY ......................................................................................................... 30
SERVICE NOTES ..................................................................................................31
ORDERING REPAIR PARTS ................................................................................32
PAGE 2
SAFETY GUIDELINES - DEFINITIONS
This manual contains information that is important for you to know and understand. This information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the
symbols to the right. Please read the manual and pay attention to these sections.
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation
which, if not avoided,
could result in death or serious
injury.
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
GASOLINE AND GASOLINE VAPORS CAN
BECOME IGNITED BY COMING INTO CON-
TACT WITH HOT COMPONENTS SUCH AS
THE MUFFLER, FROM ENGINE EXHAUST
GASES, OR FROM AN ELECTRICAL SPARK.
WHAT CAN HAPPEN HOW TO PREVENT IT
CAUTION indicates a potentially hazardous situation
which, if not avoided,
may result in minor or moder-
ate injury.
CAUTION used without the safety alert symbol indi-
cates a potentially hazardous situation which, if not
avoided,
may result in property damage.
TURN ENGINE OFF AND ALLOW IT TO
COOL BEFORE ADDING FUEL TO THE
TANK. EQUIP AREA OF OPERATION WITH
A FIRE EXTINGUISHER CERTIFIED TO
HANDLE GASOLINE OR FUEL FIRES.
RISK OF BURSTING
COMBUSTIBLE MATERIALS WHICH COME
INTO CONTACT WITH HOT ENGINE PARTS
CAN BECOME IGNITED.
UNATTENDED OPERATION OF THIS PRODUCT COULD RESULT IN PERSONAL INJURY
OR PROPERTY DAMAGE.
AIR TANK
THE FOLLOWING CONDITIONS COULD
LEAD TO A WEAKENING OF THE TANK, AND
RESULT IN A VIOLENT TANK EXPLOSION:
1. FAILURE TO PROPERLY DRAIN
CONDENSED WATER FROM THE TANK,
CAUSING RUST AND THINNING OF THE
STEEL TANK.
2. MODIFICATIONS OR ATTEMPTED
REPAIRS TO THE TANK.
ADD FUEL OUTDOORS OR IN A WELL
VENTILATED AREA. MAKE SURE THERE
ARE NO SOURCES OF IGNITION, SUCH AS
CIGARETTES NEAR REFUELING LOCATION.
OPERATE COMPRESSOR IN AN OPEN
AREA AWAY FROM DRY BRUSH, WEEDS
OR OTHER COMBUSTIBLE MATERIALS.
STORE FUEL IN A SECURE LOCATION
AWAY FROM COMPRESSOR.
ALWAYS REMAIN IN ATTENDANCE WITH
THE PRODUCT WHEN IT IS OPERATING.
DRAIN TANK DAILY OR AFTER EACH
USE. IF TANK DEVELOPS A LEAK,
REPLACE IT IMMEDIATELY WITH A NEW
TANK OR NEW COMPRESSOR OUTFIT.
NEVER DRILL INTO, WELD, OR MAKE ANY
MODIFICATIONS TO THE TANK OR ITS
ATTACHMENTS.
PAGE 3
HAZARD
RISK OF BURSTING
(cont’d)
AIR TANK
WHAT CAN HAPPEN
HOW TO PREVENT IT
RISK FROM
FLYING OBJECTS
3. UNAUTHORIZED MODIFICATIONS TO
THE UNLOADER VALVE, SAFETY
VALVE, OR ANY OTHER COMPONENTS
WHICH CONTROL TANK PRESSURE.
4. EXCESSIVE VIBRATION CAN WEAKEN
THE AIR TANK AND CAUSE RUPTURE OR
EXPLOSION. EXCESSIVE VIBRATION
WILL OCCUR IF THE COMPRESSOR IS
NOT PROPERLY MOUNTED OR IF THE
ENGINE OPERATES ABOVE RECOMMENDED RPM.
ATTACHMENTS & ACCESSORIES
EXCEEDING THE PRESSURE RATING OF
AIR TOOLS, SPRAY GUNS, AIR OPERATED
ACCESSORIES, TIRES AND OTHER
INFLATABLES CAN CAUSE THEM TO EX-
PLODE OR FLY APART, AND COULD RESULT
IN SERIOUS INJURY.
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.
THE TANK IS DESIGNED TO WITHSTAND
SPECIFIC OPERATING PRESSURES.
NEVER MAKE ADJUSTMENTS OR PARTS
SUBSTITUTIONS TO ALTER THE FACTORY SET OPERATING PRESSURES.
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.
THIS BAR CONTROLS OUTFIT VIBRATION.
FOR ESSENTIAL CONTROL OF AIR PRESSURE, YOU MUST
REGULATOR AND PRESSURE GAUGE
TO THE AIR OUTLET OF YOUR COMPRES-
SOR. FOLLOW THE EQUIPMENT MANUFACTURERS RECOMMENDATION AND
NEVER EXCEED THE MAXIMUM ALLOWABLE PRESSURE RATING OF ATTACHMENTS. NEVER USE COMPRESSOR TO
INFLATE SMALL LOW-PRESSURE OBJECTS SUCH AS CHILDREN’S TOYS,
FOOTBALLS, BASKETBALLS. ETC.
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.
INSTALL A PRESSURE
RISK TO BREATHING
BREATHING EXHAUST FUMES FROM
ENGINE WILL CAUSE SERIOUS INJURY OR
DEATH.
THE COMPRESSED AIR FROM YOUR
COMPRESSOR IS NOT SAFE FOR BREATH-
ING! THE AIR STREAM MAY CONTAIN
CARBON MONOXIDE, TOXIC VAPORS OR
SOLID PARTICLES FROM THE TANK.
SPRAYED MATERIALS SUCH AS PAINT,
PAINT SOLVENTS, PAINT REMOVER, INSECTICIDES, WEED KILLERS, ETC.. CONTAIN
HARMFUL VAPORS AND POISONS.
ALWAYS TURN THE COMPRESSOR OFF
AND BLEED PRESSURE FROM THE AIR
HOSE AND TANK BEFORE ATTEMPTING
MAINTENANCE, ATTACHING TOOLS OR
ACCESSORIES.
ALWAYS OPERATE AIR COMPRESSOR
IN A CLEAN, WELL VENTILATED AREA.
AVOID ENCLOSED AREAS SUCH AS
GARAGES, BASEMENTS, STORAGE
SHEDS, ETC., WHICH LACK A STEADY
EXCHANGE OF AIR. NEVER OPERATE
UNIT IN ENCLOSED LOCATIONS
OCCUPIED BY HUMANS OR ANIMALS.
KEEP CHILDREN, PETS AND OTHERS
AWAY FROM AREA OF OPERATION.
NEVER INHALE AIR FROM THE COMPRESSOR EITHER DIRECTLY OR FROM A
BREATHING DEVICE CONNECTED TO THE
COMPRESSOR.
WORK IN AN AREA WITH GOOD CROSSVENTILATION. READ AND FOLLOW THE
SAFETY INSTRUCTIONS PROVIDE ON
THE LABEL OR SAFETY DATA SHEETS
FOR THE MATERIAL YOU ARE SPRAYING. USE A NIOSH/MSHA APPROVED
RESPIRATOR DESIGNED FOR USE WITH
YOUR SPECIFIC APPLICATION.
PAGE 4
HAZARD
WHAT CAN HAPPEN
HOW TO PREVENT IT
RISK FROM
MOVING PARTS
RISK OF BURNS
THE ENGINE CAN START ACCIDENTALLY
IF THE FLYWHEEL IS TURNED BY HAND OR
MOVED BY PULLING ON THE STARTER
ROPE.
MOVING PARTS SUCH AS THE PULLEY,
FLYWHEEL AND BELT
SERIOUS INJURY IF THEY COME INTO
CONTACT WITH YOU OR YOUR CLOTHING.
ATTEMPTING TO OPERATE COMPRES-
WITH DAMAGED OR MISSING PARTS
SOR
OR ATTEMPTING TO REPAIR COMPRESSOR WITH PROTECTIVE SHROUDS
REMOVED CAN EXPOSE YOU TO MOVING
PARTS AND CAN RESULT IN SERIOUS
INJURY.
TOUCHING EXPOSED METAL SUCH AS THE
COMPRESSOR HEAD OR OUTLET TUBES OR
CONTACT WITH HOT ENGINE PARTS SUCH
AS THE MUFFLER CAN RESULT IN SERIOUS
BURNS.
THE GASOLINE ENGINE , THE ENGINE
MUFFLER, THE COMPRESSOR HEAD AND
TUBING BECOME VERY HOT DURING
OPERATION.
CAN CAUSE
ALWAYS
PLUG AND BLEED PRESSURE FROM
THE TANK BEFORE PERFORMING
MAINTENANCE.
NEVER OPERATE THE COMPRESSOR
WITH GUARDS OR COVERS WHICH ARE
DAMAGED OR REMOVED.
ANY REPAIRS REQUIRED ON THIS PROD-
UCT SHOULD BE PERFORMED BY
AUTHORIZED SERVICE CENTER PERSONNEL.
NEVER TOUCH ANY EXPOSED METAL
PARTS ON ENGINE OR COMPRESSOR
DURING OR IMMEDIATELY AFTER OPERATION. ENGINE AND COMPRESSOR WILL
REMAIN HOT FOR SEVERAL MINUTES
AFTER OPERATION.
DO NOT REACH AROUND PROTECTIVE
SHROUDS OR ATTEMPT MAINTENANCE
UNTIL UNIT HAS BEEN ALLOWED TO COOL.
DISCONNECT THE SPARK
PAGE 5
GENERAL INFORMATION
You have purchased a complete compressor outfit consisting of 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. An air pressure regulator may be
necessary for some of these
DESCRIPTION OF OPERATION
The gasoline engine uses a pulley and drive belt to
drive the compressor flywheel. The flywheel turns the
compressor crankshaft causing the up and down movement of the pistons in the cylinder; this up and down
movement draws and compresses the air.
On the down stroke of the piston, air is drawn in through
the air intake. The exhaust valves remain closed. On
the up stroke of the piston, both the valves are closed
and air is compressed in the cylinder. As pressure
builds in the cylinder the exhaust valve opens and the
compressed air is forced out of the cylinder through
the check valve and into the air tank. This process
continues until the air pressure reaches maximum tank
pressure.
Working air pressure becomes available when the compressor has raised the tank pressure above that required at the air discharge valve. The air intake must
be kept clear of all obstructions which could interfere
with air delivery to the compressor.
All gasoline compressor outfits are continuously running outfits controlled by tank pressure. At maximum
applications. Refer to Figure 1 for a photograph of
the compressor and to identify the major components
of the compressor.
A regularly scheduled program of preventive maintenance is necessary to insure the long life that has been
designed into your DeVilbiss compressor outfit. This
instruction manual, along with regular maintenance
will maintain your compressor outfit in good working
order. Before operating or performing any maintenance
on your outfit, refer to these publications.
tank pressure the unloader valve exhausts air to atmosphere (blowoff); tank pressure closes the check
valve retaining air pressure inside the tank. When tank
pressure drops to a pre-determined pressure, the
unloader valve closes, and air pressure opens the
check valve allowing compressed air into the tank. As
maximum tank pressure is reached, if the unloader
valve malfunctions and compressed air is not exhausted at or near its blowoff setting, the air tank safety
valve will protect the air tank against high pressure by
popping at its factory set pressure. The safety valve
popping pressure is slightly higher than the unloader
valve blowoff pressure.
This compressor outfit is equipped with a gas saving
throttle control device. When maximum tank pressure
is reached and the unloader valve opens the throttle
control is also activated, The throttle control holds the
engine at a factory set idling speed until air pressure
in the tank drops to reset or minimum tank pressure.
At reset pressure when the unloader valve closes the
throttle control is reactivated and the engine accelerates to full throttle.
PAGE 6
Engine Air
Filter
Gas
Engine
Engine Oil
Dipstick
Fuel
Tank
Pump
Air Intake
Filter
Belt
Guard
Two-Stage
Pump
Engine Oil
Drain
(Not Shown)
Throttle
Control
Unloader
Safety
Valve
Pressure
Gauge
Drain Valve
(Not Shown)
Pump Oil
Fill Plug
Pump Oil
Sight Glass
Pump Oil
Drain Plug
Air Outlet For
Discharge
Valve
Figure 1 - Typical Gasoline 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.
Immediately on equipment arrival, check for both concealed and visible damages to avoid expenses being
incurred to correct such problems. This should be done
regardless of any visible signs of damage to the shipping container. Report any damages to carrier and arrange for inspection of goods immediately.
VIBRATION MOUNTING KIT
(Stationary Compressor Outfits)
Bolting legs to a stiff surface can
cause tank rupture resulting in serious
injury or damage. Do not permanently
mount compressor to any surface with-
out using the vibration mount kit.
Portable compressor outfits may be permanently
mounted in one location such as a truck bed, if desired. A vibration mount kit is included with the outfit
for this purpose.
2. Insert the vibration mounts in the mounting holes.
Place a flat washer under the mounting surface
and secure each mount with a lockwasher and
nut. See Figure 3.
Figure 3 - Installation of Vibration Mounting Kit
3. Set the outfit on top of the vibration mounts
(the exposed threaded ends) and secure
each mount to the air tank legs with lock
washer and nut.
LOCATION OF THE COMPRESSOR
OUTFIT
1. In order to maintain adequate ventilation for
compressor cooling and to avoid contact with
pick-up truck bed, always mount the outfit at
least 8 inches from any vertical wall. Using the
holes in the air tank support legs as a guide,
mark and drill four 5/16 inch diameter holes in
the mounting surface.
To prevent excessive vibration which
may cause tank rupture or explosion,
never remove the engine stiffener bar
or increase the engine RPM. Make
sure the engine bolts and stiffener bar
nuts are tight. Do not operate the outfit
if the rubber feet are not attached.
PAGE 8
Engine exhaust contains toxic carbon
monoxide. Operate the engine in a well
ventilated area only. If inhaled, it can
cause dizziness, unconsciousness and
possibly death.
The air compressor outfit should be located as close
as possible to the point where the compressed air is
to be used. The area selected should be dry, clean,
cool, and well ventilated. Make certain that the outfit
is mounted level on a solid foundation so no strain is
imposed on the support feet or base. Keep the outfit
away from areas which have dirt, vapor, and volatile
fumes in the atmosphere which may clog and gum
the intake filter and valves causing inefficient
operation. Where this not practical a remote air
intake is recommended.
NOTE
Where a remote air intake is used, enlarge
the side of the air intake piping by one pipe
size for each 10 feet of length.
Pipe thread sealant must be used on all threads, and
all joints are to be made up tight, since small leaks in
the piping system are the largest single cause of high
operating costs.
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 required to eliminate the possibility of tank rupture.
The flywheel side of the outfit should be placed toward
the wall and protected with a totally enclosed belt
guard. In no case should the flywheel be closer than
12 to 18 inches from the wall or other obstruction that
will interfere with the flow of air through the fan blade
flywheel. See Table 1 for recommended distances. The
area should allow space on all sides for air circulation
and for ease of normal maintenance.
The compressor outfit must not be operated in any confined area where
heat from the outfit can not readily escape. Damage to the outfit may result.
The compressor crankcase and head are designed
with fins which allow for proper cooling. Clean or blow
off the fins and any other parts of the compressor outfit that collect dust or dirt. A clean compressor runs
cooler and provides longer service. Do not place rags,
containers, or other material in or against the belt guard
which will obstruct ventilation openings necessary for
proper compressor operating temperatures.
All piping should be sloped to an accessible drain
point and all outlets should be taken from the top of
the main distribution air line so that moisture cannot
enter the outlet.
The main distribution air line should not be smaller
than the compressor air discharge valve outlet. A
smaller line will restrict the flow of air. For long air
lines, refer to Table 2, Pipe Sizes for Compressed
Air Lines, for recommended pipe sizes. It is recommended that a flexible coupling be installed between
the air discharge valve outlet and main air distribution line to allow for vibration.
To remove entrained dirt, oil and water, install separator in the main distribution line, a sufficient distance
from the compressor. This will allow the air to cool to
room temperature before passing through the separator.
Additional separators or filter may be used depending on the application.
NOTE
For underground installation, bury air
lines below the frost line and avoid
pockets where condensation can
gather and freeze. Apply pressure before underground lines are covered
to make sure all pipe joints are free
from leaks.
AIR LINE PIPING
(STATIONARY COMPRESSOR OUTFITS)
The use of plastic pipe, soldered joint,
or failure to insure system capability
of flex joints and flexible hose can
result in mechanical failure, property
damage, and serious injury.
Plastic or PVC pipe is not designed for
use with compressed air. Regardless
of its indicated pressure rating, plastic
pipe can burst from air pressure. Use
only metal pipe for air distribution lines.
A typical compressed air distribution system as shown
in Figure 4, page 10 should be of sufficient pipe size
to keep the pressure drop between the supply and
point of use to a minimum. All pipes and fittings used
must be certified safe for the pressures involved.
Table 2 Pipe Sizes for Compressed Air Lines
AIR LENGTH OF PIPE LINES IN FEET
cfm 25 50 75 100 150 200 250 300
1 - 5 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
10 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
15 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4
20 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4
25 3/4 3/4 3/4 3/4 1 1 1 1
30 3/4 3/4 3/4 1 1 1 1 1
35 3/4 3/4 1 1 1 1 1 1
40 3/4 1 1 1 1 1 1 1
50 1 1 1 1 1 1 1 1
60-70 1 1 1 1 1-¼ 1-¼ 1-¼ 1-¼
80-100 1-¼ 1-¼ 1-¼ 1-¼ 1-½ 1-½ 1-½ 1-½
Pipe sizes are in inches
PAGE 9
PAGE 10
Figure 4. Typical Compressed Air Distribution System
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