GENERAL MANUAL FOR
PERMANENTLY LUBRICATED
PORTABLE/STATIONARY AIR COMPRESSOR
TABLE OF CONTENTS
SAFETY GUIDELINES ...................................................... |
1 |
WARRANTY STATEMENT .............................................. |
2 |
WARNING CHART ........................................................ |
3-4 |
GLOSSARY ........................................................................ |
5 |
DUTY CYCLE ..................................................................... |
5 |
GENERAL INFORMATION .............................................. |
5 |
ON-RECEIPT INSPECTION ............................................. |
5 |
DESCRIPTION OF OPERATION ..................................... |
6 |
ASSEMBLY (PORTABLE UNITS) .................................... |
6 |
Items Needed for Assembly .......................................... |
6 |
Installing Wheels, Handles |
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Rubber Foot Strip .......................................................... |
6 |
INSTALLATION AND BREAK-IN |
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PROCEDURES ............................................................... |
7-8 |
Location of Air Compressor .......................................... |
7 |
Air Compressor Anchoring Methods |
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(Stationary Units) .................................................... |
7 |
Lubrication and Oil ....................................................... |
7 |
Extension Cords .......................................................... |
7 |
Voltage and Current Protection .................................... |
7 |
Piping .......................................................................... |
7 |
Grounding Instructions ................................................ |
8 |
Additional Regulators & Controls ................................. |
8 |
Break-in Procedures ................................................... |
8 |
OPERATING PROCEDURES ...................................... |
8-9 |
Daily Start-up Checklist ............................................... |
8 |
MAINTENANCE ............................................................... |
9 |
Air Filter - Inspection and Replacement ....................... |
9 |
Safety Valve - Inspection ............................................. |
9 |
External Brass Check Valve Replacement .................. |
9 |
Motor ........................................................................... |
9 |
Motor Replacement - Wiring Diagram .......................... |
9 |
STORAGE ...................................................................... |
10 |
TROUBLESHOOTING GUIDE ................................. |
10-11 |
SERVICE NOTES ............................................ |
Back Cover |
SAFETY GUIDELINES - DEFINITIONS
This manual contains information thatisimportantforyoutoknowand understand.Thisinformationrelates to protecting YOUR SAFETY and
PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the symbols to the right. Please read themanualandpayattentiontothese sections.
URGENT SAFETY INFORMATION - A HAZARD |
Information for preventing damage to |
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THAT WILL CAUSE SERIOUS INJURY OR LOSS |
equipment. |
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OF LIFE. |
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IMPORTANTSAFETYINFORMATION-AHAZARD |
Information that you should pay special |
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THAT MIGHT CAUSESERIOUSINJURYORLOSS |
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OF LIFE. |
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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.
When ordering repair parts from your local Authorized Service Center, always give the following information:
•Model number of your compressor
•Part number and description of the item you wish to purchase
Retain Original Sales Receipt as Proof of Purchase for Warranty Repair Work.
DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615
MG2-OFTANK-4A REV. 9/23/99
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):
oRetain original cash register sales receipt as proof of purchase for warranty work.
oUse reasonable care in the operation and maintenance of the product as described in the Owners Manual(s).
oDeliver 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.
oAir 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.
oIf 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:
oMerchandise sold as reconditioned, floor models and/or display models. Any damaged or incomplete equipment sold "as is".
oMerchandise used as "rental" equipment.
oMerchandise 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.
oAn 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.
oMerchandise 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.
oRepair and transportation costs of merchandise determined not to be defective.
oCost associated with assembly, required oil, adjustments or other installation and start-up cost.
oANY 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.
oIMPLIED 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.
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213 Industrial Drive • Jackson, TN 38301-9615 |
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Telephone: |
1-800-888-2468 , Ext. 2 |
Form: SP-100-F - 10/28/97 |
FAX: |
1-800-888-9036 |
2—ENG
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.
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HAZARD |
WHAT CAN HAPPEN |
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HOW TO PREVENT IT |
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RISK OF BURSTING |
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THE FOLLOWING |
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COULD |
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LEAD TO A WEAKENING OF THE TANK, AND |
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RESULT IN A VIOLENT TANK EXPLOSION: |
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1. FAILURE TO PROPERLY DRAIN |
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DRAIN TANK DAILY OR AFTER EACH USE. |
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IF TANK DEVELOPS A LEAK, REPLACE IT |
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CONDENSED WATER FROM THE TANK, |
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IMMEDIATELY WITH A NEW TANK OR NEW |
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CAUSING RUST AND THINNING OF THE |
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COMPRESSOR OUTFIT. |
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STEEL TANK. |
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2. MODIFICATIONS OR ATTEMPTED |
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NEVER DRILL INTO, WELD, OR MAKE ANY |
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MODIFICATIONS |
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REPAIRS TO THE TANK. |
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ATTACHMENTS. |
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3. UNAUTHORIZED MODIFICATIONS TO |
THE TANK IS DESIGNED TO |
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SPECIFIC OPERATING PRESSURES. NEVER |
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THE PRESSURE SWITCH, SAFETY |
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MAKE ADJUSTMENTS OR PARTS SUBSTI- |
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VALVE, OR ANY OTHER COMPONENTS |
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TUTIONS TO ALTER THE FACTORY SET |
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WHICH CONTROL TANK PRESSURE. |
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OPERATING PRESSURES. |
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ATTACHMENTS |
& ACCESSORIES |
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EXCEEDING THE PRESSURE RATING OF AIR |
FOLLOW THE EQUIPMENT MANUFACTUR- |
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ERS RECOMMENDATION AND NEVER |
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TOOLS, SPRAY |
GUNS, |
AIR OPERATED |
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EXCEED THE MAXIMUM ALLOWABLE PRES- |
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ACCESSORIES, |
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SURE RATING OF ATTACHMENTS. NEVER |
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INFLATABLES CAN CAUSE THEM TO EX- |
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USE COMPRESSOR TO INFLATE SMALL |
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PLODE OR FLY APART, AND COULD RESULT |
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LOW-PRESSURE OBJECTS |
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IN SERIOUS INJURY. |
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CHILDREN’S TOYS, FOOTBALLS, |
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BASKETBALLS. ETC. |
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EXCESSIVE VIBRATION CAN WEAKEN THE |
THE COMPRESSOR MUST BE PROPERLY |
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MOUNTED, SEE INSTALLATION PROCE- |
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AIR TANK OF A STATIONARY COMPRESSOR |
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DURES. |
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AND CAUSE AN EXPLOSION. |
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RISK OF |
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ALWAYS OPERATE THE COMPRESSOR IN A |
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IT IS NORMAL FOR ELECTRICAL |
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WELL VENTILATED AREA FREE OF COM- |
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EXPLOSION OR FIRE |
CONTACTS WITHIN THE MOTOR AND PRES- |
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BUSTIBLE MATERIALS, |
GASOLINE |
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SURE SWITCH TO SPARK. |
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SOLVENT VAPORS. |
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IF ELECTRICAL SPARKS FROM COMPRESSOR |
IF SPRAYING |
FLAMMABLE |
MATERIALS, |
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LOCATE COMPRESSOR AT LEAST 20 FEET |
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COME INTO CONTACT WITH |
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AWAY FROM SPRAY AREA. AN ADDITIONAL |
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FLAMMABLE VAPORS, THEY MAY IGNITE, |
LENGTH OF HOSE MAY BE REQUIRED. |
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CAUSING FIRE OR EXPLOSION. |
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RESTRICTING ANY OF THE COMPRESSOR |
STORE FLAMMABLE MATERIALS IN A |
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SECURE LOCATION AWAY FROM COM- |
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VENTILATION OPENINGS WILL CAUSE SERI- |
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PRESSOR. |
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OUS OVERHEATING AND COULD CAUSE |
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FIRE. |
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NEVER PLACE OBJECTS AGAINST OR ON |
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TOP OF COMPRESSOR. OPERATE COM- |
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PRESSOR IN AN OPEN AREA AT LEAST 12 |
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INCHES AWAY |
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WALL |
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OBSTRUCTION |
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WOULD RESTRICT |
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THE FLOW OF FRESH AIR TO THE VENTILA- |
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TION OPENINGS. |
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RISK OF
NEVER OPERATE THE COMPRESSOR OUT- ELECTRICAL SHOCK YOUR AIR COMPRESSOR IS POWERED BY DOORS WHEN IT IS RAINING OR IN WET
ELECTRICITY. LIKE ANY OTHER ELECTRI- CONDITIONS. CALLY POWERED DEVICE, IF IT IS NOT USED
PROPERLY IT MAY CAUSE ELECTRIC NEVER OPERATE COMPRESSOR WITH
SHOCK. COVER COMPONENTS REMOVED OR DAMAGED.
CONTINUE NEXT PAGE *
3—ENG
HAZARD
RISK OF ELECTRICAL
SHOCK (cont’d)
RISK FROM
FLYING OBJECTS
RISK TO BREATHING
RISK OF FALLING
RISK FROM
MOVING PARTS
WHAT CAN HAPPEN |
HOW TO PREVENT IT |
REPAIRS ATTEMPTED BY UNQUALIFIED ANY ELECTRICAL WIRING OR REPAIRS PERSONNEL CAN RESULT IN SERIOUS REQUIRE ON THIS PRODUCT SHOULD BE
INJURY OR DEATH BY ELECTROCUTION. PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL. IN ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES.
ELECTRICAL GROUNDING: FAILURE TO
PROVIDE ADEQUATE GROUNDING TO THIS PRODUCT COULD RESULT IN SERIOUS INJURY OR DEATH FROM ELECTROCUTION. SEE GROUNDING INSTRUCTIONS.
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.
MAKE CERTAIN THAT THE ELECTRICAL CIRCUIT TO WHICH THE COMPRESSOR IS CONNECTED PROVIDES PROPER ELECTRI-
CAL 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 THE COMPRESSOR OFF AND BLEED PRESSURE FROM THE AIR LINE
BEFORE ATTEMPTING MAINTENANCE,
ATTACHING TOOLS OR ACCESSORIES.
THE COMPRESSED AIR FROM YOUR COMPRESSOR 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.
A PORTABLE COMPRESSOR CAN FALL
FROM A TABLE, WORKBENCH OR ROOF
CAUSING DAMAGE TO THE COMPRESSOR WHICH COULD RESULT IN SERIOUS INJURY.
THE COMPRESSOR CYCLES AUTOMATICALLY WHEN THE PRESSURE SWITCH IS IN
THE ON/AUTO POSITION
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
DESIGNED FOR USE WITH YOUR SPECIFIC APPLICATION.
ALWAYS OPERATE COMPRESSOR IN A STABLE SECURE POSITION TO PREVENT ACCIDENTAL MOVEMENT OF THE UNIT.
NEVER OPERATE COMPRESSOR ON A ROOF OR OTHER ELEVATED POSITION. USE ADDITIONAL AIR HOSE TO REACH HIGH LOCATIONS.
ALWAYS TURN OFF THE COMPRESSOR,
BLEED PRESSURE FROM THE AIR HOSE, AND UNPLUG FROM ELECTRICAL OUTLET BEFORE PERFORMING MAINTENANCE OR ATTACHING TOOLS AND ACCESSORIES.
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.
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.
RISK OF BURNS |
TOUCHING EXPOSED METAL SUCH AS THE |
NEVER TOUCH ANY EXPOSED METAL |
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COMPRESSOR HEAD OR OUTLET TUBE CAN |
PARTS ON COMPRESSOR DURING OR |
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RESULT IN SERIOUS BURNS. |
IMMEDIATELY AFTER OPERATION. COM- |
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PRESSOR WILL REMAIN HOT FOR SEVERAL |
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MINUTES AFTER OPERATION. |
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TMPCPOL — 3/11/97
4—ENG