DeVilbiss MG5-OLSTAT-3A User Manual

General Manual

Oil Lubricated Single Stage Stationary

Air Compressors

TABLE OF CONTENTS

SAFETY GUIDELINES ........................................... 1

WARRANTY STATEMENT ..................................... 2

WARNING CHART ................................................. 3-4

SPECIFICATIONS ................................................. 5

GLOSSARY ............................................................ 5

DUTY CYCLE ......................................................... 5

GENERAL INFORMATION .................................... 5

ON-RECEIPT INSPECTION .................................. 5

DESCRIPTION OF OPERATION ........................... 6

INSTALLATION AND

BREAK-IN PROCEDURES ................................... 6-9

Location of Air Compressor ................................. 6

Anchoring Methods ............................................. 6

Verticle Units ........................................................ 6

Voltage and Circuit Protection ............................. 7

Lubrication and Oil............................................... 7

Additional Regulators and Controls .................... 7

Break-in Procedures ............................................ 7

Wiring Instruction ................................................ 7

Piping................................................................... 8

OPERATING PROCEDURES ................................ 9-10

Daily Start-Up Checklist ............................... 9

Normal Operation ......................................... 9-10

MAINTENANCE ..................................................... 10

Routine Maintenance Schedule .................... 10

SERVICE INSTRUCTIONS ................................ 11-12

Air Filter - Inspection and

Replacement ........................................................ 11

Oil - Checking and Changing .............................. 11

Check Valve - Inspection and

Replacement ........................................................ 11

Safety Valve - Inspection and

Replacement ........................................................ 11

Belt Replacement ................................................. 11

Belt Guard - Removal and Installation ................. 11

Adjusting Belt Tension......................................... 12

Pressure Switch - Replacement ........................... 12

Motor Overload Protector - Reset ........................ 12

Pulley and Flywheel - Alignment.......................... 12

Servicing Intake and Exhaust Valves .................... 12

STORAGE ............................................................... 12

TROUBLESHOOTING GUIDE ............................... 13-15

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.

Call our Toll Free Number 1-800-888-2468, Ext 2, to obtain the location of the nearest Authorized Service Center for ordering repair parts and for warranty repairs.

When ordering repair parts from your local Authorized Service Center, always give the following information:

Retain Original Sales Receipt as Proof of Purchase for Warranty Repair Work.

MG5-OLSTAT-3A 6/18/99

SAFETY GUIDELINES - DEFINITIONS

URGENT SAFETY INFORMATION - A HAZARD THAT WILL CAUSE SERIOUS INJURY OR LOSS OF LIFE.

IMPORTANT SAFETY INFORMATION - A HAZARD THAT MIGHT CAUSE SERIOUS INJURY OR LOSS OF LIFE.

• Model number of your product

• Part number and description of the item you wish to purchase

DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615

Information for preventing damage to equipment.

Information that you should pay special attention to.

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).

Air compressors, *air tools, accessories, service parts, pressure washers, and generators used in commercial applications (income producing) are covered by a 90 day warranty.

DeVilbiss Air Power/ExCell Manufacturing will repair or replace, at DeVilbiss/ExCell’s option, products or components which have failed within the warranty period. Repair or replacement, and service calls on 60 and 80 gallon air compressors, will be handled by Authorized Warranty Service Centers and will be scheduled and serviced according to the normal work flow and business hours at the service center location, and depending on the availability of replacement parts.

All decisions of DeVilbiss Air Power Company/ExCell Manufacturing with regard to this policy shall be final.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

RESPONSIBILITY OF ORIGINAL PURCHASER (Initial User):

❏ Retain original cash register sales receipt as proof of purchase for warranty work. ❏ Use reasonable care in the operation and maintenance of the product as described in the Owners Manual(s). ❏ Deliver or ship the product to the nearest DeVilbiss Air Power/ExCell Manufacturing Authorized Warranty

Service Center. Freight costs, if any, must be paid by the purchaser.

❏ Air compressors with 60 and 80 gallon tanks only will be inspected at the site of installation. Contact the

nearest Authorized Warranty Service Center, that provides on-site service calls, for service call arrangement.

❏ If the purchaser does not receive satisfactory results from the Authorized Warranty Service Center, the

purchaser should contact DeVilbiss Air Power Company/ExCell Manufacturing.

THIS WARRANTY DOES NOT COVER:

❏ Merchandise sold as reconditioned, floor models and/or display models. Any damaged or incomplete equipment

sold "as is".

❏ Merchandise used as "rental" equipment. ❏ Merchandise that has become inoperative because of ordinary wear, misuse, freeze damage, use of improper

chemicals, negligence, accident, improper and/or unauthorized repair or alterations including failure to operate the product in accordance with the instructions provided in the Owners Manual (s) supplied with the product. *Air Tools: O-Rings and driver blades are considered ordinary wear parts, therefore, they are warranted for a period of 45 days from the date of purchase.

❏ An air compressor that pumps air more than 50% during a one hour period is considered misuse because

the air compressor is undersized for the required air demand. Maximum compressor pumping time per hour is 30 minutes.

❏ Merchandise sold by DeVilbiss Air Power/ExCell Manufacturing which has been manufactured by and identified

as the product of another company. The product manufacturer's warranty will apply.

❏ Repair and transportation costs of merchandise determined not to be defective. ❏ Cost associated with assembly, required oil, adjustments or other installation and start-up cost. ❏ ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT

FROM ANY DEFECT, FAILURE OR MALFUNCTION OF THE PRODUCT. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

❏ IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do not

allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

Form: SP-100-F - 10/28/97

213 Industrial Drive • Jackson, TN 38301-9615

Telephone: 1-800-888-2468 , Ext. 2

FAX: 1-800-888-9036

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 BURSTING

WHAT CAN HAPPEN

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.

MODIFICATIONS OR ATTEMPTED

2. REPAIRS

3. UNAUTHORIZED MODIFICATIONS TO

THE PRESSURE SWITCH, SAFETY VALVE, OR ANY OTHER COMPONENTS WHICH CONTROL TANK PRESSURE.

TO THE TANK.

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.

HOW TO PREVENT IT

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.

THE TANK IS DESIGNED TO WITHSTAND SPECIFIC OPERATING PRESSURES. NEVER

MAKE ADJUSTMENTS OR PARTS SUBSTITUTIONS TO ALTER THE FACTORY SET

OPERATING PRESSURES.

FOR ESSENTIAL CONTROL OF AIR PRESSURE, YOU MUST INSTALL A PRESSURE

REGULATOR AND PRESSURE GAUGE TO THE AIR OUTLET OF YOUR COMPRESSOR.

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.

RISK OF

EXPLOSION OR FIRE

EXCESSIVE VIBRATION CAN WEAKEN THE AIR TANK OF A STATIONARY COMPRESSOR AND CAUSE AN EXPLOSION.

IT IS NORMAL FOR ELECTRICAL CONTACTS WITHIN THE MOTOR AND PRES- SURE SWITCH TO SPARK.

IF ELECTRICAL SPARKS FROM COMPRES- SOR COME INTO CONTACT WITH FLAMMABLE VAPORS, THEY MAY IGNITE, CAUSING FIRE OR EXPLOSION.

RESTRICTING ANY OF THE COMPRESSOR VENTILATION OPENINGS WILL CAUSE SERIOUS OVERHEATING AND COULD CAUSE FIRE.

THE COMPRESSOR MUST BE PROPERLY MOUNTED, SEE INSTALLATION PROCE-

DURES.

ALWAYS OPERATE THE COMPRESSOR IN A WELL VENTILATED AREA FREE OF COM-

BUSTIBLE MATERIALS, GASOLINE OR SOLVENT VAPORS.

IF SPRAYING FLAMMABLE MATERIALS,

LOCATE COMPRESSOR AT LEAST 20 FEET AWAY FROM SPRAY AREA. AN ADDITIONAL

LENGTH OF HOSE MAY BE REQUIRED.

STORE FLAMMABLE MATERIALS IN A SECURE LOCATION AWAY FROM COMPRESSOR.

NEVER PLACE OBJECTS AGAINST OR ON TOP OF COMPRESSOR. OPERATE COMPRESSOR IN AN OPEN AREA AT LEAST 12 INCHES AWAY FROM ANY WALL OR OBSTRUCTION THAT WOULD RESTRICT

THE FLOW OF FRESH AIR TO THE VENTILATION OPENINGS.

CONTINUE NEXT PAGE

HAZARD

WHAT CAN HAPPEN

HOW TO PREVENT IT

RISK OF

ELECTRICAL SHOCK

RISK FROM

FLYING OBJECTS

YOUR AIR COMPRESSOR IS POWERED BY ELECTRICITY. LIKE ANY OTHER ELECTRI-

CALLY POWERED DEVICE,

PROPERLY IT MAY CAUSE ELECTRIC SHOCK.

REPAIRS ATTEMPTED BY UNQUALIFIED PERSONNEL CAN RESULT IN SERIOUS INJURY OR DEATH BY ELECTROCUTION.

ELECTRICAL GROUNDING:

PROVIDE ADEQUATE GROUNDING TO THIS PRODUCT COULD RESULT IN SERIOUS INJURY OR DEATH FROM ELECTROCUTION.

SEE GROUNDING INSTRUCTIONS.

COMPRESSED AIR STREAM CAN CAUSE

THE

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.

IF IT IS NOT USED

FAILURE TO

NEVER OPERATE THE COMPRESSOR OUTDOORS WHEN IT IS RAINING OR IN WET CONDITIONS.

NEVER OPERATE COMPRESSOR WITH COVER

COMPONENTS ANY ELECTRICAL WIRING OR REPAIRS RE-

QUIRED ON THIS PRODUCT

PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL IN ACCORDANCE WITH

NATIONAL AND LOCAL ELECTRICAL CODES.

MAKE CERTAIN THAT THE ELECTRICAL CIRCUIT TO WHICH THE COMPRESSOR IS CONNECTED PROVIDES PROPER ELECTRICAL GROUNDING, CORRECT VOLTAGE AND ADEQUATE FUSE PROTECTION.

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.

ALWAYS TURN OFF THE COMPRESSOR, BLEED PRESSURE FROM THE AIR HOSE AND

TANK, AND DISCONNECT FROM POWER SOURCE BEFORE PERFORMING MAINTE-

NANCE OR ATTACHING TOOLS AND ACCESSORIES.

REMOVED OR DAMAGE.

SHOULD BE

RISK TO BREATHING

RISK FROM

MOVING PARTS

RISK OF BURNS

THE COMPRESSED AIR FROM YOUR COM- PRESSOR IS NOT SAFE FOR BREATHING! THE AIR STREAM MAY CONTAIN CARBON MONOXIDE, TOXIC VAPORS OR SOLID PARTICLES.

SPRAYED MATERIALS SUCH AS PAINT, PAINT SOLVENTS, PAINT REMOVER, INSECTICIDES, WEED KILLERS, ETC.. CONTAIN HARMFUL VAPORS AND POISONS.

THE COMPRESSOR CYCLES AUTOMATI-

CALLY WHEN THE PRESSURE SWITCH IS IN THE ON/AUTO POSITION.

MOVING PARTS CAN CAUSE SERIOUS INJURY

OR DAMAGE IF THEY COME INTO CONTACT WITH YOU OR YOUR CLOTHING.

ATTEMPTING TO OPERATE OR REPAIR COMPRESSOR WITH PROTECTIVE SHROUDS REMOVED CAN EXPOSE YOU TO MOVING PARTS AND ELECTRICAL SHOCK.

TOUCHING EXPOSED METAL SUCH AS THE COMPRESSOR HEAD OR OUTLET TUBE CAN RESULT IN SERIOUS BURNS.

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 PROVIDED ON THE LABEL OR SAFETY DATA SHEETS FOR THE MATERIAL YOU ARE SPRAYING. USE A NIOSH/MSHA APPROVED RESPIRATOR DE-

SIGNED FOR USE WITH YOUR SPECIFIC APPLICATION.

ALWAYS TURN OFF THE COMPRESSOR, BLEED PRESSURE FROM THE AIR HOSE AND TANK, AND DISCONNECT FROM POWER SOURCE BEFORE PERFORMING MAINTE-

NANCE OR ATTACHING TOOLS AND ACCESSORIES.

DO NOT REMOVE THE PROTECTIVE COVERS FROM THIS PRODUCT. NEVER OPERATE THE COMPRESSOR WITH GUARDS OR COVERS

WHICH ARE DAMAGED OR REMOVED.

ANY REPAIRS REQUIRED ON THIS PRODUCT

SHOULD BE PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL.

NEVER TOUCH ANY EXPOSED METAL PARTS ON COMPRESSOR DURING OR IMMEDIATELY AFTER OPERATION. 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.

SCWORPOL — 7/23/97

SPECIFICATIONS

Refer to Outfit Part Listing for the specifications of your compressor. Use only a fuse or circuit breaker that is the same rating as the branch circuit the air compressor is operated on. If the compressor is connected to a circuit protected by fuses, use dual element time delay fuses, as noted in the Outfit Parts Listing.

GLOSSARY

Improper electrical installation of this product may void its warranty and your fire insurance. Have circuit wiring performed by qualified personnel such as a licensed electrician who is familiar with the current national electric code and any prevailing local electrical codes.

CFM: Cubic feet per minute.

SCFM: Standard cubic feet per minute; a unit of measure of air

delivery.

PSIG: Pounds per square inch gauge; a unit of measure of pressure.

ASME: American Society of Mechanical Engineers; made, tested, inspected and registered to meet the standards of ASME.

California Code: Unit may comply with California Code 462 (L) (2) / (M) (2). Specification/Model label is on the side of the tank on units that comply with California Code.

DUTY CYCLE

All DeVilbiss Air Power manufactured air compressors should be operated on not more than a 50% duty cycle. This means an air compressor that pumps air more than 50% of one hour, is

GENERAL INFORMATION

You have purchased an air compressor unit consisting of an aluminum 2 cylinder, single-stage air compressor pump (with cast iron sleeves), an air tank, and associated controls and instruments. You will also find a Parts Manual.

Your air compressor can be used for operating paint spray guns, air tools, caulking guns, grease guns, air brushes, sandblasters, inflating tires and plastic toys, or spraying weed killers, insecticides, etc. An air pressure regulator is required for most of these applications.

An air line filter is usually required for removal of moisture and oil vapor in compressed air when a paint spray gun is used.

To Lock Out Power: Place a lock on the line power switch so no one else can turn on the power.

Cut-In Pressure: While the motor is off, air tank pressure drops as you continue to use your accessory or air tool. When the tank pressure drops to a certain low level the motor will restart automatically. The low pressure at which the motor automatically restarts is called “cut-in pressure.”

Cut-Out Pressure: When you turn on your air compressor and it begins to run, air pressure in the air tank begins to build. It builds to a certain high pressure before the motor automatically shuts off

- protecting your air tank from pressure higher than its capacity. The high pressure at which the motor shuts off is called “cut-out pressure.”

considered misuse, because the air compressor is undersized for the required air demand. Maximum compressor pumping time per hour is 30 minutes.

An in-line lubricator is usually required for air tools to prolong tool life.

Separate air transformers which combine the functions of air regulation and/or moisture and dirt removal should be used where applicable.

A regularly scheduled program of preventive maintenance will help provide the long life that has been designed into your compressor outfit. Before operating or performing any maintenance on your compressor, refer to this manual and your Outfit Parts Manual. To keep your compressor in good working order, refer to these publications often and perform preventive maintenance steps as recommended.

ON-RECEIPT INSPECTION

Each air compressor outfit is carefully tested and checked before shipment. With improper handling, damage may result in transit and cause problems in compressor operation.

Immediately upon arrival, check equipment 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. If this product was shipped directly to you, report any damages to carrier and arrange for inspection of goods immediately.

For the location or a listing of the nearest DeVilbiss Air Power Authorized Warranty Service Center, call our toll free number at

1-800-888-2468, Ext. 2.

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