Grainger CIAO 6, BIG PIONEER, TIGER, BI-TANK, BI-TANK WHEELED Operating Instructions Manual

...
Serial no.:
N° de série: N° de serie:
ELECTRIC AIR COMPRESSORELECTRIC AIR COMPRESSOR
ELECTRIC AIR COMPRESSOR
ELECTRIC AIR COMPRESSORELECTRIC AIR COMPRESSOR
COMPRESSEUR D’AIR ÉLECTRIQUE
COMPRESOR DE AIRE ELÉCTRICOCOMPRESOR DE AIRE ELÉCTRICO
COMPRESOR DE AIRE ELÉCTRICO
COMPRESOR DE AIRE ELÉCTRICOCOMPRESOR DE AIRE ELÉCTRICO
a
Operating Instructions
Instructions d’utilisation et fonctionnement Instrucciones de uso y funcionamiento
Warnings for safe use of this air compressor are included in this manual
! Le présent manuel mentionne les avis pour une utilisation en toute sécurité du compresseur. ¡En el presente manual están incluidas las advertencias para un uso seguro del compresor!
197CC7900 - ED.2 - 01/2010
INTRODUCTION..........................................................................3
SAFETY ALERT...........................................................................3
INSPECTION ...............................................................................3
1. SAFETY WARNINGS ...............................................................4
2. AIR COMPRESSOR FEATURES..............................................8
3. PREPARATION........................................................................10
4. OPERATION ............................................................................11
5. MAINTENANCE .......................................................................12
6. TROUBLESHOOTING ............................................................. 12-14
SPECIFICATIONS........................................................................41
2
INTRODUCTION
Congratulations on the purchase of your new Air Compressor! You can be assured your Air Compressor was constructed with the highest level of precision and accuracy . Each component has been rigorously tested by technicians to ensure the quality , endurance and performance of this air compressor.
This operator’s manual was compiled for your benefit. By reading and following the simple safety, installation and operation, maintenance and troubleshooting steps described in this manual, you will receive years of troublefree operation from your new Air Compressor. The contents of this manual are based on the latest product information available at the time of publication. The manufacturer reserves the right to make changes in price, color , materials equipment, specifications or models at any time without notice.
SAFETY ALERT!
A ”DANGER, W ARNING or CAUTION” safety warning will be surrounded by a ”SAFETY ALERT BOX”. This box is used to designate and emphasize Safety Warnings that must be followed when operating this air compressor. Accompanying the safety warnings are “Signal Words” which designate the degree or level of hazard seriousness. The “Signal Words” used in this manual are as follows:
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 injury.
death or serious
ENGLISH
CAUTION: Indicates a potentially hazardous situation which, if not avoided MAY result in minor or moderate injury or damage to the air compressor.
The symbols set to the left of this paragraph are “Safety Alert Symbols”. These symbols are used to call attention to items or procedures that could be dangerous to you or other persons using this equipment.
ALWAYS PROVIDE A COPY OF THIS MANUAL TO ANYONE USING THIS EQUIPMENT. READ ALL INSTRUCTIONS IN THIS MANUAL AND ANY INSTRUCTIONS SUPPLIED BY MANUFACTURERS OF SUPPORTING EQUIPMENT BEFORE OPERA TING THIS AIR COMPRESSOR AND ESPECIALL Y POINT OUT THE “SAFETY WARNINGS” TO PREVENT THE POSSIBILITY OF PERSONAL INJURY TO THE OPERA TOR.
INSPECTION
Unbox the air compressor and write in the serial number in the space provided below. Inspect for signs of obvious or concealed freight damage. Be sure that all damaged parts are replaced and any mechanical problems are corrected prior to the operation of the air compressor.
SERIAL NUMBER__________________________________________
Please have the following information available for all service calls:
1. Model Number
2. Serial Number
3. Date and Place of Purchase
3
1. SAFETY W ARNINGS
READ ALL SAFETY W ARNINGS BEFORE USING AIR COMPRESSOR
HAZARD
RISK
ELECTRIC
SHOCK
OR
ELECTROCUTION
POTENTIAL CONSEQUENCE
Serious injury or death could occur if the air compressor is not properly grounded. Y our air compressor is powered by electricity and may cause electric shock or electrocution if not used properly .
Electrical shock may occur from electrical cord.
Electrical shock may occur if air compressor is not operated properly .
Serious injury or death may occur if electrical repairs are attempted by unqualified persons.
PREVENTION
Make sure the air compressor is plugged
into a properly grounded outlet which provides correct voltage and adequate fuse protection.
Check power cord for signs of crushing,
cutting or heat damage. Replace faulty cord before use.
Keep all connections dry and off the
ground. Do not allow electrical cords to lay in water or in such a position where water could come in contact with them. Do not touch plug with wet hands.
Do not pull on the electrical cord to
disconnect from the outlet.
Never operate air compressor in wet
conditions or outdoors when it is raining.
Never operate air compressor with safety
guards/covers removed or damaged.
Any electrical wiring or repairs performed
on this air compressor should be done by Authorized Service Personnel in accordance with National and Local electrical codes.
Before opening any electrical enclosure,
always shut off the air compressor, relieve pressure and unplug the air compressor from the power source. Allow air compressor to cool down. Never assume the air compressor is safe to work on just because it is not operating. It could restart at any time!
RISK OF
EXPLOSION
OR FIRE
Serious injury or death may occur from normal electrical sparks in motor and pressure switch
Serious injury may occur if any air compressor ventilation openings are restricted, causing the air compressor to overheat and start on fire.
4
Always operate air compressor in a well
ventilated area free of flammable vapors, combustible dust, gases or other combustible materials.
If spraying flammable material, locate the
air compressor at least 20 feet away from the spray area. (An additional hose may be required.)
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.
1. SAFETY W ARNINGS
READ ALL SAFETY WARNINGS BEFORE USING AIR COMPRESSOR
1. SAFETY WARNINGS1. SAFETY WARNINGS
1. SAFETY WARNINGS
1. SAFETY WARNINGS1. SAFETY WARNINGS
HAZARD RISK OF
BURSTING
RISK TO
BREATHING
POTENTIAL CONSEQUENCE
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 could occur from inhaling compressed air. 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.
PREVENTION
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 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.
Never inhale air from the air compressor
either directly or from a breathing device connected to the air compressor.
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.
ENGLISH
RISK OF
BURNS
RISK
OF FLYING
OBJECTS
Serious injury could occur from touching exposed metal parts. These areas can remain hot for some time after the air compressor is shutdown.
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.
Never allow any part of your body or other
materials to make contact with any exposed metal parts on the air compressor.
Always wear OSHA required “Z87” 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 compressor
unattended. Shut off air compressor and relieve pressure before attempting maintenance, attaching tools or accessories.
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.
5
1. SAFETY W ARNINGS
READ ALL SAFETY W ARNINGS BEFORE USING AIR COMPRESSOR
1. SAFETY WARNINGS1. SAFETY WARNINGS
1. SAFETY WARNINGS
1. SAFETY WARNINGS1. SAFETY WARNINGS
HAZARD
RISK FROM
MOVING P ARTS
RISK FROM
NEGLIGENCE
RISK
OF AIR
COMPRESSOR
DAMAGE
POTENTIAL CONSEQUENCE
Risk of bodily injury from moving parts. This air compressor cycles automatically when the pressure switch is in the “On/Auto” position.
Risk of injury from negligent use.
Risk of major repair.
PREVENTION
Always turn off air compressor. Bleed
pressure from the air hose and unplug from electrical outlet before performing maintenance. All repairs to the air compressor should be made by an Authorized Service person. Never assu­me the air compressor is safe to work on just because it is not operating. It could restart at any time!
Do not operate without protective covers/
guards. Replace damaged covers/guards before using the air compressor.
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.
Do not operate air compressor without an
air filter.
Do not operate air compressor in a corro-
sive environment.
Do not incline the air compressor
transversely or longitudinally more than 10°.
Ensure the oil level is above the minimum
notch and below the maximum notch on the dipstick. If low, add with ISO 100 compressor pump oil.
Always operate the air compressor in a
stable, secure position to prevent air compressor from falling.
Follow all maintenance instructions listed
in this manual.
SAVE THESE INSTRUCTIONS
6
BI-TANK
BI-T ANK WHEELED
2. AIR COMPRESSOR FEATURES
-
+
ENGLISH
3
10
6
SCOUT
4
a
5
11
7 89
17
15
1
2
14
16
13
12
1. Pressure Switch
2. Thermal Overload / Reset
3. Air Intake Filter
4. Air Compressor Pump
5. Safety V alve
6. Air tank drain valve
7. Tank Pressure Gauge
8. Outlet Pressure Gauge
9. Pressure Regulator
10. Oil Dipstick 1 1. Oil Drain
12. Discharge Line
13. Electric Power Cord
14. Ventilation Openings / Protective Shroud
15. Quick coupling
16. Intake valve
17. Cold start valve
7
BIG PIONEER
TIGER
2. AIR COMPRESSOR FEATURES
CIAO 6
17
2
10
11
12
16
8
15
1. Pressure Switch
2. Thermal Overload / Reset
3. Air Intake Filter
4. Air Compressor Pump
5. Safety V alve
6. Air tank drain valve
7. Tank Pressure Gauge
8. Outlet Pressure Gauge
9. Pressure Regulator
4
3
14
5
7
13
6
10. Oil Dipstick 1 1. Oil Drain
12. Discharge Line
13. Electric Power Cord
14. Ventilation Openings / Protective Shroud
15. Quick coupling
16. Intake valve
17. Cold start valve
8
2. AIR COMPRESSOR FEATURES
1) MOTOR/PRESSURE SWITCH: This switch is used to
start or stop the air compressor . Moving the switch to the “On” position will provide automatic power to the pressure switch which will allow the motor to start when the air tank pressure is below the factory set “cut-in” pressure. When in the “ON ” position, the pressure switch stops the motor when the air tank pressure reaches the factory set “cut out” pressure. For safety purposes, this switch also has a pressure release valve located on the side of the switch designed to automatically release compressed air from the air compressor pump head and its discharge line when the air compressor reaches “cut-out” pressure or is shut off. This allows the motor to restart freely . Moving the switch to the “Off” position will remove power from the pressure switch and stop the air compressor.
OFF
OFF
2) MOTOR THERMAL OVERLOAD:
The electric motor has a manual thermal overload protector. If the motor overheats for any reason, the thermal overload will cut off power, thus preventing the motor from being damaged. Wait until the motor is cool before pressing the thermal overload button to reset and begin working again.
3) AIR INTAKE FILTER: This filter is designed to clean air coming into the pump. T o ensure the pump continually receives a clean, cool, dry air supply this filter must always be clean and ventilation opening free from obstructions. The filter can be removed for cleaning by using warm, soapy water. Rinse the filter and air dry. Replace filter when necessary .
AUTO
ON
compressed air is forced out through the exhaust valves, into the discharge line, through the check valve and into the air tank.
5) SAFETY RELIEF VALVE:
This valve is designed to prevent system failures by relieving pressure from the system when the compressed air reaches a predetermined level. The valve is preset by the manufacturer and must not be modified in any way. T o verify the valve is working properly , pull on the ring. Air pressure should escape. When the ring is released, it will reseat.
6) AIR T ANK DRAIN VALVE:
The drain valve is used to remove moisture from the air tank(s) after the air compressor is shut off. NEVER attempt
to open the drain valve when more than 10 PSI of air pressure is in the air tank! To open the drain valve, turn the knob
counterclockwise.
7) AIR T ANK PRESSURE GAUGE: The air t ank pressure gauge (A) indicates the reserve air pressure in the air tank (s).
8) OUTLET PRESSURE GAUGE: The outlet pressure gauge (B) indicates the air pressure available at the outlet side of the regulator. This pressure is controlled by the regulator and is always less or equal to the air tank pressure.
9) PRESSURE REGULA TOR: The air pressure coming from the air tank is controlled by the regulator knob (C). Turn the pressure regulation knob clockwise to increase discharge pressure, and counterclockwise to decrease discharge pressure.
B
C
C
A
ENGLISH
4) AIR COMPRESSOR PUMP: To compress air, the
pistons move up and down in the cylinders. On the downstroke, air is drawn in through the air intake valves while the exhaust valves remain closed. On the upstroke, air is compressed, the intake valves close and
A
B
10) OIL DIPSTICK: The dipstick will register the amount of oil in the pump. Oil level should be checked on a daily basis to ensure it does not exceed the maximum notch or fall below the minimum notch on the dipstick
9
3. PREP ARATION
INITIAL SET -UP
1. Read safety warnings before setting-up air compressor.
2. Ensure the oil level is above the minimum notch and below the maximum notch on the dipstick. If low, add compressor pump oil.
LOCATION
CAUTION: In order to avoid damaging the air compressor, do not incline the air compressor
transversely or longitudinally more than 10°.
Place air compressor at least 12 inches away from obstacles that may prevent proper ventilation. Do not place air compressor in an area:
where there is evidence of oil or gas leaks. where flammable gas vapors or materials may be present.
WARNING:
Serious injury or death may occur if electrical sparks from motor and pressure switch come in contact with flammable vapors, combustible dust, gases or other combustible materials. When using the air compressor for spray painting, place the air compressor as far away from the work area as possible, using extra air hoses instead of extension cords.
where air temperatures fall below 32°F or exceed 104°F. where extremely dirty air or water could be drawn into the air compressor.
ELECTRICAL
DANGER: Improper connection of the equipment-grounding conductor can result in a risk of shock
or electrocution. Check with a qualified electrician or service personnel if you are in doubt as to whether the outlet is properly grounded. Do not use any type of adapter with this product. If repair or replacement of the cord or plug is necessary , do not connect the grounding wire to either flat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.
WARNING: This product must be grounded. If there should be a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This product is equipped with a cord having an equipment-grounding conductor and a grounding type plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances.
The Manufacturer DOES NOT RECOMMEND THE USE OF EXTENSION CORDS as this can create power
loss and overheating of the motor. Use of an additional air hose is recommended rather than an extension cord. If use of an extension cord is unavoidable, it should be plugged into a GFCI found in circuit boxes or protected receptacles. When using an extension cord, observe the following:
Cable Length Wire Gauge Up to 25 feet 12 AWG Up to 100 feet 10 AWG Up to 150 feet 8 AWG Up to 250 feet 6 AWG
Use only 3-blade extension cords that have 3-blade grounding-type plugs and 3-slot cord connectors that will accept the plug from the product. Use only extension cords having an electrical rating not less than the rating of the product. Do not use damaged extension cords. Examine extension cord before using and replace if damaged. Do not abuse extension cord and do not yank on any cord to disconnect. Keep cord away from heat and sharp edges. Always shut off the air compressor switch before removing the plug from the receptacle.
10
4. OPERATION
PRE-ST ART CHECKLIST :
1. Check oil level. Add if necessary.
2. Remove any moisture in the air compressor air tank. Remove excessive pressure with an air tool, then open the
air tank drain valve in the bottom of the air tank. Close tightly when drained.
WARNING: Risk of bodily injury. NEVER attempt to open the drain valve when more than 10 PSI of air pressure is in the air tank!
3. Make sure the air compressor Motor Switch is in the “OFF” position.
4. Make sure all safety valves are working correctly .
5. Make sure all guards and covers are in place and securely mounted.
ST ART-UP
Read safety warnings before performing operation.
1. Ensure the lever on the pressure switch box is in the “OFF” position.
2. Plug the power cord into a grounded outlet.
3. Move the lever on the pressure switch box to the “AUTO” position.
4. Set pressure by adjusting the pressure regulator knob counterclockwise for less pressure and clockwise for
more pressure.
5. If you notice any unusual noise or vibration, stop the air compressor and refer to “Troubleshooting”.
ENGLISH
SHUTDOWN
1. To stop the air compressor, move the lever on the pressure switch box to the “OFF” position. NEVER stop the
air compressor by unplugging it from the power source. This could result in risk of electrocution.
2. Drain air from the air tanks by releasing air with an attached air tool or by pulling on the safety relief valve ring.
3. Once pressure in the air tanks register under 10 pounds, open the drain valve under each air tank to drain any
moisture.
4. Allow the air compressor to cool down.
5. Wipe air compressor clean and store in a safe, warm area.
11
5. MAINTENANCE
Read the instruction manual before performing maintenance. The following procedures must be performed when stopping the air compressor for maintenance or service.
1. Turn off air compressor.
WARNING: Never assume the air compressor is safe to work on just because it is not operating. It could restart at any time!
2. Disconnect cord from main power supply.
3. Open all drains.
4. Wait for the air compressor to cool before starting service.
MAINTENANCE CHART
PROCEDURE DAILY WEEKLY MONTHLY 200 HOURS
Check pump oil level X Oil leak inspection X Drain condensation in air tank(s) X X Check for unusual noise/vibration X Check for air leaks X Inspect air filter X Clean exterior of compressor X Check safety relief valve X Change pump oil* X Replace air filter X
*The pump oil must be changed after the first 50 hours of operation and every 200 hours or 3 months, whichever comes first. We recommend using a straight weight detergent oil that is specifically blended for air compressor.
6. TROUBLESHOOTING
CHECKLIST
PROBLEM
Air compressor will
not start
Guest complains of
excessive trippings of reset button
Reset button for thermal overload protection has tripped
Tank pressure has reached top-end pressure switch setting
Oil too thick due to storage in colder temperatures.
Machine is brand new and needs to be “broken in”.
Improper gauge of extension cord is being used.
CAUSE
REMEDY
Locate reset (red) button, and press it firmly until click is heard. Evaluate oil weight, use of extension cords etc.
Drain or use compressed air until low-end pressure setting is reached.
Change oil to synthetic blend or winter grade air compressor oil, and/or open tank drain(s), and allow pump to run fro 30/60 seconds unloaded before attemping to cycle machine normally .
Open tank drain to start, and keep drain slightly open to force additional cycling until break-in period is reaching (40 hrs.)
Make sure guest is using 12 gauge (maximum 25’) or 10 gauge (maximum 50’) extension cord.
Intake filter or gauge
is broken
Shipping damage or inadvertent guest error.
For additional informations and/or different problems, please read carefully the following pages
Contact after sales service for replacement
12
6. TROUBLESHOOTING
CAUSE
Symptom 1. Motor will not run or restart.
Power cord not plugged in. Motor/Pressure switch in “OFF” position. Motor thermal overload switch has tripped.
Fuse blown or circuit breaker has tripped.
Wrong gauge wire or length of extension cord.
Pressure release valve on motor/pressure switch has not unloaded pump head pressure Tank check valve stuck open
REMEDY
Plug cord into grounded outlet. Move switch to “AUTO” position. Turn air compressor off, wait until motor is cool, then press
motor thermal overload (red) button firmly until click is heard.
Replace fuse or reset circuit breaker. Check for proper fuse; only “Fusetron” type T fuses are
acceptable. Check for low voltage conditions. Disconnect any other electrical appliances from circuit or
operate air compressor on its own branch circuit. Check chart on page #10 for proper gauge wire and cord
length. Bleed the line by moving the switch to the “Off” position Remove and clean or replace
ENGLISH
Defective motor, capacitor, pressure switch, or check valve.
Symptom 2. Noisy operation
Lack of oil in the pump. Carbon deposits on pistons or valves. Bearing, piston or connecting rod failure.
Symptom 3. When in the start/stop option, motor runs continuously
Air compressor is incorrectly sized.
Symptom 4. Air continues to leak at motor/pressure switch relief valve af ter motor stop s.
Defective check valve, is stuck open.
Symptom 5. Air continues to leak at motor/pressure switch release valve while motor is running.
Defective motor/pressure switch. Replace
Symptom 6. Air leaks from safety relief valve.
Possible defective safety relief valve.
Contact Customer Service.
Add correct amount of oil. Check for bearing damage. Remove cylinder head and inspect. Clean or replace. STOP THE COMPRESSOR!
Contact Customer Service.
Limit the air pressure to the capacity of the air compressor. Either use a smaller tool or a larger air compressor.
Remove, clean or replace.
Operate safety relief valve manually by pulling on ring. If it still leaks, it should be replaced.
Excessive air tank pressure.
Defective gasket Replace and torque head bolts to 8 ft./lbs
Defective pressure switch. Replace.
Symptom 7. Air leaks at pump
13
6. TROUBLESHOOTING
CAUSE REMEDY
Symptom 8. Air leaks at fittings.
Fittings are not tight enough.
Symptom 9. Air leaks in air tank
Defective or rusted air tank Air t ank must be replaced. Do not attempt to repair tank.
Symptom 10. Air blowing from intake filter
Damaged inlet (reed) valve
Symptom 11. Insufficient pressure at air tool or accessory.
Pressure regulator knob not turned to high enough pressure or defective pressure regulator.
Symptom 11. Insufficient pressure at air tool or accessory.
Restricted air intake filter . Air leaks. Hose or hose connections are too small or long. Air compressor is not large enough for air requirement.
Symptom 12. Air compressor not making enough air.
Tighten fittings where air can be heard escaping. Check fittings with soapy water solution. Do not overtighten.
Contact Customer Service.
Adjust pressure regulator knob to proper setting or replace.
Clean or replace. Check for leaks and repair. Replace with larger hose or connectors. Check the accessory air requirement. If it is higher than
the CFM or pressure supply of the air compressor, you need a larger air compressor.
Restricted air intake filter . Defective (reed) valve.
Restricted check valve
Symptom 13. Excessive oil consumption in pump.
Restricted air intake filter . Air compressor on unlevel surface.
Crankcase overfilled with oil. Plugged oil dipstick vent. Oil leaks. Worn piston rings or scored cylinder .
Symptom 14. Oil has milky appearance.
Water in oil due to condensation. Change oil and move air compressor to a less humid
Clean or replace. Drain air tank and measure pump up time. Compare to
specifications. If lower, remove pump head and inspect valve plate, clean or replace.
Clean or replace
Clean or replace. Do not incline the air compressor more than 10° in any
direction while running. Drain oil. Refill to proper level with oil. Clean. Repair. Contact Customer Service.
environment.
Condensation in air tank caused by high level of atmospheric humidity or air compressor is not run long enough.
Symptom 15. Moisture in discharge air.
Drain air tank after every use. Drain air tank more often in humid weather and use an air line filter.
14
Loading...
+ 30 hidden pages