Grip rite GR2540LR, GR2540 User Manual

OPERATING MANUAL AND PARTS LIST

GR2540 & GR2540LR

COMPRESSOR’S

TABLE OF CONTENTS

Table of Contents..........................................................................1

Safety Symbols .............................................................................2

Safety Instructions........................................................................3

GR2540 Specifications..................................................................5

GR2540LR Specifications............................................................. 6

Compressor Description ..............................................................7

Compressor Parts Description.....................................................8

Set Up........................................................................................... 10

Operation..................................................................................... 12

Maintenance ................................................................................ 13

GR2540 Schematic...................................................................... 14

GR2540 Parts List - Pump .....................................................15-16

GR2540LR Schematic.................................................................17

GR2540LR Parts List - Pump.................................................18-19

Troubleshooting.......................................................................... 20

Storage......................................................................................... 22

Warranty.......................................................................................23

WARNING

This manual contains important safety and operating instructions that must be followed. You must read and understand this manual before operating this compressor. Failure to follow all instructions can result in serious injury to operator and bystanders, or damage to compressor and attachments.

SAFETY SYMBOLS

The safety symbols used on the compressor’s safety labels and in this manual provide an important visual reminder of basic safety rules, and the hazards that may arise if all safety and operating instructions are not followed. Make sure you understand the meaning of each of these symbols, and protect yourself and others by obeying all safety and operating instructions on warning labels and in this manual.

SYMBOL DESCRIPTION

SAFETY ALERT SYMBOL

Calls attention to important safety information and provides an alert to potential safety hazards.

HOT SURFACE HAZARD

Hot surfaces can cause serious burn injury if touched. Let unit cool before handling.

MOVING PARTS/ENTANGLEMENT HAZARD

Contact with moving parts can cause serious injury. Keep guards and protective covers in place.

INHALATION HAZARD

Compressed air can contain carbon monoxide or other harmful gases. Do not use compressor to provide air for breathing.

BURST HAZARD

Over-pressurization caused by tampering with controls can cause serious injury or death from explosion.

SHOCK HAZARD

Contact with live electrical components can cause shock, serious injury, or death from electrocution. Use a properly grounded power source.

EXPLOSION HAZARD

Electrical sparks from unit can ignite flammable liquids and vapors. Use compressor in a well ventilated area free from explosive vapors.

FIRE HAZARD

Keep compressor 20’ feet away from spray area when spraying flammable materials. Operate unit away from obstructions that could block ventilation.

HIGH PRESSURE AIR HAZARD

Release of pressurized air can cause serious injury if directed against body. Never use air pressure higher than recommended for tool or accessory.

SAFETY INSTRUCTIONS

WEAR ANSI Z87.1 APPROVED EYE PROTECTION - Always wear approved eye protection equipment that

provides both front and side eye protection when operating or servicing the compressor.

DO NOT EXCEED MAXIMUM RECOMMENDED OPERATING PRESSURE OF AIR-POWERED TOOLS OR OTHER EQUIPMENT BEING USED - Spray guns and other low to medium pressure equipment can burst,

causing serious injury to user and bystanders. Read and follow all manufacturers' pressure recommendations before connecting tools, sprayers, or other equipment to compressor. Use extreme care when using the compressor with tires, inner tubes, and other inflatables, as excessive pressure or rapid inflation can cause these items to burst.

CONNECT COMPRESSOR POWER CORD ONLY TO A PROPERLY GROUNDED POWER OUTLET USING AN APPROVED 3-PRONG GROUNDED EXTENSION CORD - Using an improperly grounded outlet or extension

cord can result in shock or electrocution. Electrical wiring, outlets, extension cords, and current protection devices such as fuses and circuit breakers must meet local electrical and safety codes, as well the requirements of the National Electrical Code. A ground-fault circuit interrupter (GFCI) device may be required for compressor use outdoors, in garages, and in damp locations.

USE AN EXTENSION CORD THAT IS PROPERLY SIZED - Using an undersize cord can result in overheating of cord and short-circuiting, resulting in fire and damage to property. Use a UL-listed extension cord rated to safely handle the power requirements of the compressor .

DO NOT OPERATE IF FLAMMABLE VAPORS ARE PRESENT - The electric motor and pressure switch may produce sparks, which can ignite flammable vapors and cause fire or explosion. Flammable vapors from gasoline, solvents, adhesives, and other chemicals may drift some distance from the source, or build up in low areas. Operate the compressor only in well-ventilated areas that are free of flammable vapors.

DO NOT OPERATE IN THE RAIN OR IN WET AREAS - Operating an electric compressor in wet conditions can result in severe shock or electrocution. Operate only in dry conditions, using a properly grounded power outlet that conforms to local and national electrical code requirements. An outlet with ground-fault circuit interrupter (GFCI) protection is recommended for use outdoors or in garages, and may be required by local electrical codes.

DO NOT TOUCH COMPRESSOR HEAD OR TUBING WHEN UNIT IS OPERATING - Normal compressor operation will cause tubing and other components to become extremely hot. Contact with hot parts can cause serious burns. Allow unit to cool before handling or performing service.

SAFETY INSTRUCTIONS

NEVER DIRECT COMPRESSED AIR AT ANY BODY PARTS - Compressed air can penetrate skin, or force dirt

and debris into eyes, causing serious injury. Never place hands or body parts over the air discharge opening of a pressurized nozzle or fitting. Use care when connecting and disconnecting air hose to attachments, pneumatic tools, and other air-powered devices.

KEEP FLAMMABLE SPRAYS AWAY FROM SPARKS AND OTHER SOURCES OF IGNITION - Spraying flammable liquids such as oil-base paints, sealers, and finishes near sparks, open flame, and other sources of ignition such as pilot lights, appliances, water heaters, furnaces, etc. can result in explosion and fire. Turn off all pilot lights, and avoid using electrical appliances, heaters, torches, and other equipment that may produce sparks or flame. Keep compressor as far away from spraying area as possible by using an air hose of sufficient length to prevent spray mist from being ignited by electrical sparks from compressor operation.

DO NOT TAMPER WITH COMPRESSOR PRESSURE SWITCH SETTINGS - The pressure switch settings set at the factory provide the maximum safe operating pressure recommended for this compressor. Altering these settings can result in over-pressurization, risk of tank, hose, and pneumatic equipment failure, and serious injury to operator and bystanders.

USE AIR HOSE RATED FOR 150 PSI OR GREA TER - Air hose must be rated to safely handle maximum compressor pressure. Air hose that does not meet minimum pressure requirements can rupture, releasing high pressure air. Replace a cracked or leaking air hose immediately to prevent serious injury from contact with high pressure air streams.

DISCONNECT POWER CORD AND RELIEVE TANK PRESSURE BEFORE SERVICING UNIT – Never perform service or maintenance on any part of the compressor while the unit is pressurized or connected to power. The compressor can start automatically, causing serious injury. Open tank drains slowly to allow air to escape, and keep clear of air stream.

DO NOT MODIFY COMPRESSOR – Altering the compressor in any way may create a serious safety hazard, and result in serious injury to operator and bystanders. If compressor does not work properly, stop using unit immediately. Return unit to an authorized service center for repairs if problem cannot be remedied by following troubleshooting instructions in this manual.

SPECIFICATIONS GR2540

DESCRIPTION SPECIFICATION

Horsepower 2.5 (Peak)

Voltage 115V Amperage 14 Hz 60 Phase Single RPM 3450 Capacity Tanks 1 Air Storage Capacity 4 Gallons Maximum Air Pressure 150 PSI CFM 5.7 cfm @ 40 PSI

4.5 cfm @ 90 PSI Pressure Switch Settings Pressure Switch - ON 110 PSI Pressure Switch - OFF 150 PSI Compressor Pump

Motor

Cylinders 1 Compression Stage 1 Lubrication Splash Oil Type Compressor Oil SAE 30W (ISO 100)* Crankcase Aluminum Bearings Ball Cylinder Cast Iron Valves Stainless Steel Reed Head Aluminum Filter Canister Dimensions Weight 88 Lbs. Shipping Weight 92 Lbs. Size ( L X W X H) 23.6" X 22" X 20"

*PROVIDED WITH UNIT

SPECIFICATIONS GR2540LR

DESCRIPTION SPECIFICATION

Horsepower 2.5 (Peak)

Voltage 115V Amperage 12 Hz 60 Phase Single RPM 1725 Capacity Tanks 1 Air Storage Capacity 4 Gallons Maximum Air Pressure 150 PSI CFM 5.3 cfm @ 40 PSI

4.2 cfm @ 90 PSI Pressure Switch Settings Pressure Switch - ON 110 PSI Pressure Switch - OFF 150 PSI Compressor Pump

Motor

*PROVIDED WITH UNIT

COMPRESSOR DESCRIPTION

COMPRESSOR PARTS DESCRIPTION

KEY DESCRIPTION FUNCTION

1 Heavy Duty Power Cord Provides power to compressor motor

2 Frame Protects compressor components 3 Compressor Pump Compresses air 4 Reset Switch Protects motor from overloads 5 Dipstick (not on GR254LR) Used to check oil level in pump crankcase 6 Hex Head Wheel Bolt Secures wheels to compressor frame 7 Wheel Assembly Large pneumatic tires allow easy rolling 8 Safety Relief Valve Releases excessive air pressure from tank 9 Air Storage Tank Stores compressed air 10 Rubber Foot Provides stable footing, reduces vibration 11 Handle Latch Secures handle position for easy transport 12 Air Tank Drain Allows moisture to be drained from tank 13 Handle Extends for ease of transport 14 Air Outlet Fittings (2) Allows quick connection of air hoses 15 Regulator Control Knob Adjust discharge air pressure setting 16 Tank Air Pressure Gauge Indicates air pressure in storage tank 17 Air Outlet Pressure Gauge Indicates air pressure at air outlet fittings 18 Compressor Top Plate Protects compressor components 19 On-Off Switch Turns compressor on and off 20 Tank Warning Label Provides important safety information 21 Cooling System Cools compressor components 22 Motor Shroud Protects motor and compressor 23 3-Prong Grounding Plug Safely grounds equipment when properly

connected to a grounded power source. 24 Motor Label Provides important motor information 25 Air Filter Filters intake air to remove dust and debris 26 Power Cord Retainer Secures power cord for storage

SET UP

WARNING:

Before being used for the first time, your new compressor requires a simple set-up procedure that will help your unit deliver years of trouble-free service. Failure to follow all initial set-up instructions may result in serious damage to your compressor, property damage, or serious injury to operator and bystanders. Do not start compressor until all set-up steps have been performed.

1. Remove compressor and wheel assemblies from carton.

2. Install wheels on wheel mounts at bottom of frame using hex head wheel bolts. Tighten bolts securely with 1-1/4” wrench.

3. Unscrew shipping plug from crankcase. Add non-detergent oil to compressor and check oil level in sight glass or with dipstick. Oil level must be between “L” (Low) and “H” (High) marks on flat area of dipstick. Crankcase capacity is ll.8 oz. (350 ml). Use chart below for correct viscosity:

Air Temperature Viscosity 14 – 40 F SAE 20 (ISO 68) 40 – 80 F SAE 30 (ISO 100)

4. Install dipstick in crankcase, and tighten securely before starting compressor. Make sure black seal is in place between dipstick and crankcase to prevent loss of oil during compressor operation or movement.

5. Check power outlet circuit for correct capacity. Compressor requires 120V, Single Phase, 14 Amps, 60 Hz. Fuses or circuit breakers must be rated accordingly.

6. Use an extension cord with 3-prong grounding plug. Extension cord must be sized to prevent power loss and overheating of the motor:

Cord Length Wire Gauge Size Up to 25 ft. 12 ga. Up to 100 ft. 10 ga. Up to 150 ft. 8 ga. Up to 250 ft. 6 ga.

7. Pull handle out until locking hole in handle is aligned with locking pin on base of compressor. Lock handle in extended position with locking pin, and use handle to wheel compressor to desired area of operation.

8. Position compressor on a secure, stable surface, no more than 10 degrees off level.

9. Plug power cord in, and unscrew Air Tank Drain at the bottom of the air tank. Start compressor by moving On/Off lever up to the “ON” position. Allow compressor to run for 10 minutes without stopping. Watch for excessive vibration or unusual noise while compressor motor is running. If unit vibrates excessively or makes unusual noise, shut compressor off by moving On/Off lever to “OFF” position. Refer to trouble-shooting chart for corrective action. If no excessive vibration is noted, tighten the Air Tank Drain, allow unit to fill the air tanks, and proceed to step 10.

10. Check operation of Pressure Relief Valve by pulling release ring out to exhaust air pressure from tank. Release ring and allow pressure relief valve to reseat. Contact your dealer if Pressure Relief Valve does not operate properly.

11. Compressor is now ready for regular operation.

OPERATION

Operating Compressor

1. Move On/Off lever to the "OFF" position.

2. Plug the power cord into the power receptacle.

3. Move On/Off lever to the "ON" position.

4. Leave compressor in “ON” position while in use.

5. To stop compressor, move On/Off lever to the "OFF" position. DO NOT stop compressor by unplugging power cord.

6. Adjust outlet air pressure to desired setting by turning pressure regulator knob “C.” Turn knob clockwise (+) to increase air pressure, counterclockwise (-) to decrease air pressure. Outlet air pressure is indicated by gauge (B). Tank pressure is indicated by gauge (A)

7. Connect air hoses to quick-connect fittings (D) using a male quick-connect fitting. To connect air hose simply insert male hose connector. To release air hose, push hose fitting in, push back outer ring on compressor fitting, and pull male hose connector out.

WARNING

High pressure air will escape when hose is disconnected. Keep face away from fittings to prevent dirt and debris from being blown into eyes. Always wear safety glasses with side shields to

protect eyes when using compressor.

MAINTENANCE

Maintenance Schedule

DANGER

Never perform maintenance on the compressor when it is in the “ON” position. Always place On/Off switch in “OFF” position, disconnect power cord from power source, drain air tanks, and allow unit to cool first. Performing service procedures on a compressor with pressurized tanks, or in the “ON” position, can result in serious injury.

MAINTENANCE CHART

Interval Maintenance Required

Check lubricant level and fill crankcase as needed Drain moisture from tanks daily. Open drain slowly and let air pressure

bleed down gradually before opening drain valve completely. Use care when tipping compressor to drain tanks.

Daily

Weekly

Perform a visual inspection of compressor. Make sure motor cover is in place, and all components are in good condition. Check compressor power cord and plug for damage. Don't use compressor if cord or plug is damaged.

Check for unusual noise or vibration, and have problem corrected. Contact your Grip-Rite dealer for service.

Open air filter cap and clean air filter. Replace filter if damaged or excessively dirty.

Check Pressure Relief Valve for proper operation. With tank pressurized, pull on Pressure Relief Valve ring. Air must exhaust when ring is pulled. Release ring - air must stop exhausting when ring is released.

Check for leaks, cracks, or corrosion on tank, fittings, and tubing. Discontinue use of equipment if leaks or other major problems are found, and repair unit before placing back into service.

3 Months/

300 Hours

Change compressor oil and air filter. Clean/blow off compressor pump fins and motor. Check for air leaks at connections, and tighten fittings if necessary.

Check tank for cracks, corrosion, leaks, or other damage. Never use a compressor with a damaged tank.

Check warning labels for legibility, and replace if necessary. Contact your Grip-Rite dealer for replacement labels.

GR2540 COMPRESSOR SCHEMATIC (Silver Tank)

PUMP

TANK/FRAME

GR2540 COMPRESSOR PARTS LIST - PUMP

REF NO. DESCRIPTION QTY. PART#

1 CYLINDER HEAD 1 PACP408 2 ALLEN BOLT 4 PACP396 3 SPRING WASHER 10 PACP3 4 AIR FILTER 1 PACP409 5 FILTER ELEMENT 1 PACP410 6 CYLINDER HEAD GASKET 1 PACP9 7 IN. & EX. VALVE ASSEMBLY 1 PACP82 8 VALVE SEAT GASKET 1 PACP411

9 CYLINDER 1 PACP412 10 HEXAGON NUT 2 PACP20 11 SPRING WASHER 2 PACP21 12 DOUBLE HEAD SCREW 2 PACP22 13 CYLINDER GASKET 1 PACP14 14 PISTON RING SET 1 PACP413 15 PISTON SET 1 PACP414 16 ROD 1 PACP415 17 CRANKSHAFT & BALANCER 1 PACP416 18 MOTOR SET 1 PACP417 19 FRONT COVER GASKET 1 PACP418 20 FRONT COVER 1 PACP419 21 BOLT 4 PACP27 22 BOLT 1 PACP420 23 O-RING 1 PACP421 24 DIPSTICK SET 1 PACP24 25 DIPSTICK GASKET 1 PACP25 26 COOLING FAN 1 PACP422 27 SHROUD 1 PACP423 28 HEXAGON BOLT SET 4 PACP424 29 PLATE WASHER 4 PACP124 30 HEXAGON BOLT SET 4 PACP425 31 STARTING CAPACITOR 1 PACP426 32 RUNNING CAPACITOR 1 PACP427 33 CIRCUIT BREAKER 1 PACP67 34 EXHAUST ELBOW 1 PACP428

GR2540 COMPRESSOR PARTS LIST - TANK/FRAME

REF NO. DESCRIPTION QTY. PART#

35 AIR TANK 1 PACP429 36 TANK WHEEL 2 PACP430 37 TANK WHEEL BOLT 2 PACP431 38 RUBBER PAD 2 PACP432 39 PLATE WASHER 2 PACP45 40 HEXAGON BOLT 2 PACP42 41 DRAIN VALVE 1 PACP35 42 GRIP SET 1 PACP433 43 CHECK VALVE 1 PACP434 44 TUBE 1 PACP435 45 UNLOADING ELBOW 1 PACP48 46 UNLOADING TUBE 1 PACP436 47 PRESSURE SWITCH 1 PACP437 48 PRESSURE RELIEF VALVE 1 PA CP438 49 EXHAUST ELBOW 1 PACP439 50 TUBE 1 PACP440 51 REGULATOR 1 PACP388 52 PRESSURE GAUGE 2 PACP441 53 ELBOW 1 PACP190 54 PLUG 2 PACP56 55 CABLE 1 PACP442 56 POWER CABLE 1 PACP336 57 PANEL 1 PACP443 58 HANDLE BUSHING 2 PACP444 59 BOLT 16 PACP396 60 BODY SEAT 1 PACP445 61 HEXAGON BOLT SET 2 PACP446 62 AUTO RELIEF VALVE 1 PACP447 63 STRAIN RELIEF BUSHING 1 PACP383 64 STRAIN RELIEF BUSHING 1 PACP63 65 STRAIN RELIEF BUSHING 1 PACP337 66 QUICK COUPLER 2 PACP448

GR2540LR COMPRESSOR SCHEMATIC (Black Tank)

PUMP

TANK/FRAME

GR2540 COMPRESSOR PARTS LIST - PUMP

REF NO. DESCRIPTION QTY. PART #

1 CYLINDER HEAD 1 PACP1 2 ALLEN BOLT SET 4 PACP496 3 ELBOW GASKET 1 PACP4 4 EXHAUST ELBOW 1 PACP5 5 ALLEN BOLT SET 2 PACP6 6 AIR FILTER SET 1 PACP471 7 FILTER ELEMENT 1 PACP8 8 VALVE ASSEMBLY 1 PACP472

9 CYLINDER 1 PACP473 10 DOUBLE HEAD SCREW SET 2 PACP474 11 CYLINDER GASKET 1 PACP14 12 PISTON RING SET 1 PACP475 13 PISTON SET 1 PACP476 14 ROD 1 PACP17 15 CRANKSHAFT & BALANCER 1 PACP477 16 MOTOR SET 1 PACP478 17 FRONT BEARING SEAT GASKET 1 PACP479 18 FRONT COVER 1 PACP480 19 BOLT 4 PACP27 20 PLUG 1 PACP26 21 OIL SIGHT GAUGE SET 1 PACP481 22 BREATHER SET 1 PACP166 23 CENTRIFUGAL SWITCH SET 1 PACP482 24 COOLING FAN 1 PACP483 25 SHROUD 1 PACP32 26 HEXAGON BOLT 6 PACP424 27 THERMAL PROTECTOR 1 PACP67 28 STARTING CAPACITOR 1 PACP74 29 RUNNING CAPACITOR 1 PACP229 30 AIR TANK 1 PACP484 31 DRAIN VALVE 1 PACP485 32 TANK WHEEL 2 PACP486 33 TANK WHEEL BOLT 2 PACP487

GR2540 COMPRESSOR PARTS LIST – TANK AND FRAME

REF NO. DESCRIPTION QTY. PART #

34 RUBBER PAD SET 2 PACP488 35 GRIP 1 PACP489 36 RUBBER GRIP 1 PACP490 37 CHECK VALVE 1 PACP47 38 UNLOADING ELBOW 1 PACP48 39 UNLOADING TUBE 1 PACP491 40 TUBE 1 PACP339 41 PRESSURE SWITCH 1 PACP492 42 PRESSURE RELIEF VALVE 1 PACP438 43 STRAIN RELIEF BUSHING 1 PACP337 44 STRAIN RELIEF BUSHING 1 PACP63 45 POWER CABLE 1 PACP336 46 REGULATOR 1 PACP493 47 PRESSURE GAUGE 2 PACP441 48 EXHAUST ELBOW 1 PACP439 49 TUBE 1 PACP440 50 PLUG 4 PACP56 51 QUICK COUPLER 2 PACP448 52 BODY SEAT 1 PACP494 53 HEXAGON BOLT SET 2 PACP495 54 PANEL 1 PACP443 55 BOLT 16 PACP396 56 HANDLE BUSHING 2 PACP444 57 CABLE 1 PACP442

TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Compressor won't start

Compressor runs continuously; doesn't shut off

Safety relief valve pops open

Circuit breaker tripped Reset breaker Fuse blown in power supply branch

circuit. Power turned off. Turn power on Pressure release valve on

motor/pressure switch has not unloaded pump head pressure.

Defective cord or plug Replace Motor thermal overload tripped Turn compressor off, allow motor

Motor, capacitor, pressure switch, or check valve inoperable.

Drain plug open Close drain plug Safety relief valve stuck open Replace Air fitting on hose stuck open Repair or replace Pressure switch misadjusted Have authorized service dealer

Replace fuse. Use Fusetron type “T” fuse only.

Bleed line by moving switch to “OFF” position. Pull switch to “ON” position to restart unit.

to cool, and reset overload button.

Contact authorized service dealer.

adjust pressure switch.

Pressure switch inoperable Have switch serviced by

authorized service dealer.

Air leaks from safety relief valve Valve stuck or inoperable Pull on ring and release.

Replace valve if leak continues.

Tool, sprayer, or other accessory doesn't work properly.

Unit runs continuously Air usage greater than compressor

Air leaks at motor/pressure switch release valve while motor is running

Air leaks at motor/pressure switch release valve after motor stops.

Air pressure too low or too high Adjust regulator to provide

pressure recommended by product manufacturer.

Check CFM requirements of air

output capacity Oil level low Check for leaks, and add oil Noisy operation Internal wear or damage Have unit serviced by authorized

Switch inoperable Have authorized service dealer

tool or accessory being used.

service dealer.

replace switch

TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Air leaks at fittings Fittings loose Tighten fittings Air leaks at compressor head Head bolts loose Tighten bolts securely Air blows out of inlet filter Damaged reed valve Have unit serviced by authorized

service dealer

Insufficient pressure at air tool or accessory

Oil consumption excessive

Crankcase oil appears milky when dipstick is checked

Moisture in discharge air Excessive condensation in air tank Drain tank more frequently. Tip

Air intake filter dirty Clean or replace filter Air leaks Check unit for leaks and correct

as needed.

Air hose too small or too long Use large diameter air hose and

larger capacity fittings.

Reed valve worn or damaged Have authorized service dealer

replace. Air intake filter dirty Clean or replace filter Compressor positioned on uneven

surface Oil leakage Have authorized service dealer

Worn cylinder or piston rings. Have authorized service dealer

Water in oil from condensation Change crankcase oil.

Position compressor on level

surface

repair unit.

unit when draining tank to drain

all water.

STORAGE

 Open tank drain valve and allow all air pressure to escape.  Drain all moisture out of tanks, and close drain valves.  Disconnect air hose and wind hose carefully for storage

 Inspect compressor for wear, damage, or missing parts, and have repairs made

promptly.

 Store unit in a dry, cool place.  Storage in vehicles or trailers - secure the compressor to keep it from tipping or being

damaged by contact with other equipment. Make sure gauges, fittings, and knobs are clear of objects that could cause damage.

 Do not place heavy objects on top of compressor.

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Grip rite GR2540LR, GR2540 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual