GENERAL MANUAL FOR OIL LUBRICATED SINGLE STAGE PORTABLE AIR COMPRESSOR
TABLE OF CONTENTS
SAFETY GUIDELINES ............................................ |
1 |
WARRANTY ........................................................... |
2 |
WARNING CHART ............................................... |
3-4 |
GLOSSARY ............................................................. |
5 |
DUTYCYCLE .......................................................... |
5 |
GENERAL INFORMATION ................................... |
5 |
ON-RECEIPT INSPECTION .................................. |
5 |
DESCRIPTION OF OPERATION .......................... |
5-6 |
ASSEMBLY ............................................................. |
6 |
Items Needed for Assembly ................................ |
6 |
Installing Rubber Foot Strip and Wheels ............ |
6 |
Installing Handle ................................................. |
6 |
INSTALLATION AND |
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BREAK-IN PROCEDURES ..................................... |
6-8 |
Location of Air Compressor ................................ |
7 |
Outside Location ................................................. |
7 |
Voltage and Circuit Protection ........................... |
7 |
Extension Cords .................................................. |
7 |
Lubrication and Oil .............................................. |
7 |
Grounding Instructions ....................................... |
7 |
Piping ................................................................... |
8 |
Additional Regulators and Controls ................... |
8 |
Break-in Procedures ........................................... |
8 |
OPERATING PROCEDURES ................................. |
8 |
Daily Start-Up Checklist ..................................... |
8 |
Normal Operation ................................................ |
8 |
MAINTENANCE .................................................... |
9 |
Routine Maintenance Schedule ........................ |
9 |
SERVICE INSTRUCTIONS ..................................... |
9-11 |
Air Filter - Inspection and |
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Replacement ....................................................... |
9 |
Oil - Checking and Changing ............................. |
9 |
Check Valve - Inspection and |
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Replacement ....................................................... |
9 |
Safety Valve - Inspection and |
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Replacement ....................................................... |
9 |
Belt Guard - Removal and Installation ............... |
10 |
Belt Replacement ............................................... |
10 |
Pressure Switch - Replacement ......................... |
10 |
Motor Overload Protector - Reset ...................... |
10 |
Pulley and Flywheel - Alignment ........................ |
10 |
Servicing Intake and Exhaust Valves ................. |
10 |
STORAGE ............................................................... |
1 1 |
TROUBLESHOOTING GUIDE ........................... |
11-13 |
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.
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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attention to. |
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THATMIGHT 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
MG3-OLPORT-3A 11/6/98
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.
ANYINCIDENTAL,INDIRECTORCONSEQUENTIALLOSS,DAMAGE, OR EXPENSETHATMAYRESULT FROMANYDEFECT,FAILUREORMALFUNCTIONOFTHEPRODUCT. Somestates donotallowthe exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
IMPLIEDWARRANTIES,INCLUDINGTHOSEOFMERCHANTABILITYANDFITNESSFORAPARTICULAR PURPOSE,ARELIMITEDTOONEYEARFROMTHEDATEOFORIGINALPURCHASE. Somestatesdonot 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
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 |
AIR TANK |
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THE FOLLOWING CONDITIONS COULD LEAD |
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TO A WEAKENING OF THE TANK, AND RESULT |
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IN A VIOLENT TANK EXPLOSION: |
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1. FAILURE TO PROPERLY DRAIN |
DRAIN TANK DAILY OR AFTER EACH USE. |
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CONDENSED WATER FROM THE TANK, |
IF TANK DEVELOPS A LEAK, REPLACE IT |
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CAUSING RUST AND THINNING OF THE |
IMMEDIATELY WITH A NEW TANK OR NEW |
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STEEL TANK. |
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COMPRESSOR OUTFIT. |
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2. MODIFICATIONS OR ATTEMPTED |
NEVER DRILL INTO, WELD, OR MAKE ANY |
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REPAIRS TO THE TANK. |
MODIFICATIONS TO THE TANK OR ITS |
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ATTACHMENTS. |
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3. UNAUTHORIZED MODIFICATIONS TO THE |
THE TANK IS DESIGNED TO WITHSTAND |
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PRESSURE SWITCH, SAFETY VALVE, OR |
SPECIFIC OPERATING PRESSURES. |
NEVER |
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ANY OTHER COMPONENTS WHICH |
MAKE ADJUSTMENTS OR PARTS SUBSTI- |
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CONTROL TANK |
PRESSURE. |
TUTIONS TO ALTER THE FACTORY SET |
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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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TOOLS, SPRAY GUNS, AIR OPERATED ACCES- |
ERS RECOMMENDATION AND NEVER |
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SORIES, TIRES AND OTHER INFLATABLES CAN |
EXCEED THE MAXIMUM ALLOWABLE PRES- |
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CAUSE THEM TO EXPLODE OR FLY APART, |
SURE RATING OF |
ATTACHMENTS. |
NEVER |
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AND COULD RESULT IN SERIOUS INJURY. |
USE COMPRESSOR TO INFLATE SMALL |
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LOW-PRESSURE OBJECTS SUCH AS |
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CHILDREN’S TOYS, |
FOOTBALLS, |
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BASKETBALLS. ETC. |
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RISK OF |
IT IS NORMAL FOR ELECTRICAL CONTACTS |
ALWAYS OPERATE THE COMPRESSOR IN A |
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WITHIN THE MOTOR AND PRESSURE SWITCH |
WELL VENTILATED AREA FREE OF COM- |
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EXPLOSION OR FIRE |
TO SPARK. |
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BUSTIBLE MATERIALS, GASOLINE OR SOL- |
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VENT VAPORS. |
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IF ELECTRICAL SPARKS FROM COMPRESSOR |
IF SPRAYING FLAMMABLE MATERIALS, LO- |
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COME INTO CONTACT WITH FLAMMABLE |
CATE COMPRESSOR AT LEAST 20 FEET |
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VAPORS, THEY MAY IGNITE, CAUSING FIRE |
AWAY FROM SPRAY AREA. AN ADDITIONAL |
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OR EXPLOSION. |
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LENGTH OF HOSE MAY BE REQUIRED. |
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STORE FLAMMABLE MATERIALS IN A |
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SECURE LOCATION AWAY FROM COM- |
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PRESSOR. |
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RESTRICTING ANY OF THE COMPRESSOR |
NEVER PLACE OBJECTS AGAINST OR ON |
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VENTILATION OPENINGS WILL CAUSE SERI- |
TOP OF COMPRESSOR. |
OPERATE COM- |
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OUS OVERHEATING AND COULD CAUSE |
PRESSOR IN AN OPEN AREA AT LEAST 12 |
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FIRE. |
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INCHES |
AWAY FROM |
ANY |
WALL OR |
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OBSTRUCTION THAT WOULD RESTRICT THE |
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FLOW OF FRESH AIR TO THE VENTILATION |
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OPENINGS. |
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RISK OF |
YOUR AIR COMPRESSOR IS POWERED BY |
NEVER OPERATE THE COMPRESSOR OUT- |
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ELECTRICAL SHOCK |
ELECTRICITY. LIKE ANY OTHER ELECTRI- |
DOORS |
WHEN IT IS RAINING |
OR |
IN WET |
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CALLY POWERED DEVICE, IF IT IS NOT USED |
CONDITIONS. |
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PROPERLY IT MAY CAUSE ELECTRIC SHOCK. |
NEVER |
OPERATE |
COMPRESSOR |
WITH |
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COVER COMPONENTS REMOVED OR DAM- |
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AGED. |
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CONTINUE NEXT PAGE *
3
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HAZARD |
WHAT CAN HAPPEN |
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HOW TO PREVENT IT |
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RISK OF |
REPAIRS |
ATTEMPTED |
BY |
UNQUALIFIED |
ANY ELECTRICAL WIRING OR REPAIRS |
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ELECTRICAL SHOCK |
PERSONNEL |
CAN |
RESULT |
IN SERIOUS |
REQUIRED |
ON |
THIS PRODUCT |
SHOULD BE |
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INJURY OR DEATH BY ELECTROCUTION. |
PERFORMED BY AUTHORIZED SERVICE CEN- |
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(cont’d) |
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TER PERSONNEL IN ACCORDANCE WITH |
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ELECTRICAL |
GROUNDING: |
FAILURE TO |
NATIONAL AND LOCAL ELECTRICAL CODES. |
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MAKE CERTAIN THAT THE ELECTRICAL |
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PROVIDE ADEQUATE GROUNDING TO THIS |
CIRCUIT TO WHICH THE COMPRESSOR IS |
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PRODUCT COULD RESULT IN SERIOUS |
CONNECTED PROVIDES PROPER ELECTRI- |
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INJURY OR DEATH FROM ELECTROCUTION. |
CAL GROUNDING, CORRECT VOLTAGE AND |
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SEE GROUNDING INSTRUCTIONS. |
ADEQUATE |
FUSE |
PROTECTION. |
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RISK FROM |
THE COMPRESSED AIR STREAM CAN CAUSE |
ALWAYS |
WEAR |
ANSI |
Z87.1 |
APPROVED |
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SOFT TISSUE DAMAGE TO EXPOSED SKIN |
SAFETY GLASSES WITH SIDE SHIELDS WHEN |
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FLYING OBJECTS |
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AND CAN PROPEL DIRT, CHIPS, LOOSE |
USING THE COMPRESSOR. |
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PARTICLES AND SMALL OBJECTS AT HIGH |
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SPEED, RESULTING IN PROPERTY DAMAGE |
NEVER POINT ANY NOZZLE OR SPRAYER |
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OR PERSONAL INJURY. |
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TOWARD ANY PART OF THE BODY OR AT |
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OTHER PEOPLE OR ANIMALS. |
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ALWAYS TURN THE COMPRESSOR OFF AND |
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BLEED PRESSURE FROM THE AIR HOSE AND |
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TANK |
BEFORE |
ATTEMPTING |
MAINTENANCE, |
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ATTACHING TOOLS OR ACCESSORIES. |
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RISK TO BREATHING |
THE COMPRESSED |
AIR |
FROM YOUR COM- |
NEVER INHALE AIR FROM THE COMPRESSOR |
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PRESSOR IS NOT SAFE FOR BREATHING! THE |
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EITHER |
DIRECTLY |
OR |
FROM |
A |
BREATHING |
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AIR STREAM MAY CONTAIN CARBON MONOX- |
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DEVICE CONNECTED TO THE COMPRESSOR. |
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IDE, TOXIC VAPORS OR SOLID PARTICLES. |
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SPRAYED MATERIALS SUCH AS PAINT, PAINT |
WORK |
IN |
AN |
AREA |
WITH |
GOOD |
CROSS- |
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VENTILATION. |
READ |
AND |
FOLLOW |
THE |
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SOLVENTS, |
PAINT REMOVER, |
INSECTICIDES, |
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SAFETY INSTRUCTIONS |
PROVIDED |
ON |
THE |
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WEED KILLERS, ETC.. |
CONTAIN HARMFUL |
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LABEL |
OR |
SAFETY |
DATA |
SHEETS FOR |
THE |
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VAPORS AND POISONS. |
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MATERIAL |
YOU |
ARE |
SPRAYING. |
USE A |
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NIOSH/MSHA APPROVED RESPIRATOR DE- |
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SIGNED FOR USE WITH YOUR SPECIFIC |
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APPLICATION. |
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RISK OF FALLING |
A PORTABLE COMPRESSOR CAN FALL FROM |
ALWAYS OPERATE COMPRESSOR IN A |
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A TABLE, WORKBENCH OR ROOF CAUSING |
STABLE SECURE POSITION TO PREVENT |
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DAMAGE TO THE COMPRESSOR WHICH |
ACCIDENTAL MOVEMENT OF THE UNIT. NEVER |
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COULD RESULT IN SERIOUS INJURY. |
OPERATE COMPRESSOR ON A ROOF OR |
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OTHER ELEVATED POSITION. USE ADDI- |
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TIONAL AIR HOSE TO REACH HIGH LOCA- |
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TIONS. |
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RISK FROM |
THE COMPRESSOR CYCLES AUTOMATI- |
ALWAYS TURN OFF THE COMPRESSOR, |
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MOVING PARTS |
CALLY WHEN THE PRESSURE SWITCH IS IN |
BLEED PRESSURE FROM THE AIR HOSE AND |
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THE ON/AUTO POSITION. |
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TANK, AND UNPLUG FROM ELECTRICAL |
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OUTLET BEFORE PERFORMING MAINTE- |
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NANCE OR ATTACHING TOOLS AND ACCES- |
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SORIES. |
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MOVING PARTS CAN CAUSE SERIOUS IN- |
DO NOT REMOVE THE PROTECTIVE COVERS |
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JURY OR DAMAGE IF THEY COME INTO |
FROM THIS PRODUCT. |
NEVER OPERATE THE |
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CONTACT WITH YOU OR YOUR CLOTHING. |
COMPRESSOR WITH GUARDS OR COVERS |
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ATTEMPTING TO OPERATE OR REPAIR |
WHICH ARE DAMAGED OR REMOVED. |
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ANY REPAIRS REQUIRED ON THIS PRODUCT |
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COMPRESSOR WITH PROTECTIVE SHROUDS |
SHOULD BE PERFORMED BY AUTHORIZED |
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REMOVED CAN EXPOSE YOU TO MOVING |
SERVICE CENTER |
PERSONNEL. |
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PARTS AND ELECTRICAL SHOCK. |
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RISK OF BURNS |
TOUCHING EXPOSED METAL SUCH AS THE |
NEVER TOUCH ANY EXPOSED METAL PARTS |
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COMPRESSOR HEAD OR OUTLET TUBE CAN |
ON COMPRESSOR DURING OR IMMEDIATELY |
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RESULT IN SERIOUS BURNS. |
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AFTER |
OPERATION. |
COMPRESSOR |
WILL |
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REMAIN HOT FOR SEVERAL MINUTES AFTER |
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OPERATION. |
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TMPCPOL — 5/1/97
4
GLOSSARY
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.
U.L. Listed: Products with the U.L. mark are listed by Underwriters Laboratories, Inc. (U.L.). Samples of these products have been evaluated by U.L. and meet the applicable U.L. Standards of Safety.
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.
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 re-starts 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.”
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 considered misuse, because the air compressor is undersized for the required air demand. Maximum compressor pumping time per hour is 30 minutes.
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, wheels, handle, associated controls and instruments.
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, 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.
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.
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.
DESCRIPTION OF OPERATION
Drain Valve: The drain valve is located at the base of the air tank and is used to drain condensation at the end of each use.
Motor Thermal Overload Protector: The electric motor has an automatic thermal overload protector. If the motor overheats for any reason, the thermal overload protector will shut off the motor. The motor must be allowed to cool before restarting.
ON/AUTO - OFF Switch (Pressure Switch): Turn this switch ON to provide automatic power to the pressure switch and OFF to remove power at the end of each use. The pressure switch automatically starts the motor when the air tank pressure drops below the factory set “cut-in” pressure. It stops the motor when the air tank pressure reaches the factory set “cut-out” pressure.
Air Intake Filter: This filter is designed to clean air coming into the pump. This filter must always be clean and ventilation openings free from obstructions. See "Maintenance".
Air Compressor Pump: To compress air, the pistons moves up and down in the cylinder. On the downstroke, air is drawn in through the air intake valves. The exhaust valve remains closed. On the upstroke of the piston, air is compressed. The intake valves close and compressed air is forced out through the exhaust valve, through the outlet tube, through the check valve and into the air tank. Working air is not available until the compressor has raised the air tank pressure above that required at the air outlet.
Check Valve: When the air compressor is operating, the check valve is “open”, allowing compressed air to enter the air tank. When the air compressor reaches “cut-out” pressure, the check valve “closes”, allowing air pressure to remain inside the air tank.
Pressure Release Valve: The pressure release valve located on the side of the pressure switch, is designed to automatically release compressed air from the compressor head and the outlet tube when the air compressor reaches “cut-out” pressure or is shut off. If the air is not released, the motor will try to start, but will be unable to. The pressure release valve allows the motor to restart freely. When the motor stops running, air will be heard escaping from the valve for a few seconds. No air should be heard leaking when the motor is running, or continuous leaking after unit reaches cutout pressure.
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 high pressure by “popping out” at its factory set pressure (slightly higher than the pressure switch cut-out setting).
5