Powerfist 5E-1-60V, 5E-2-80V, 10E-2-120H-3-230, 10E-2-120H-1-230, 10E-2-120H-3-575 User Manual

TABLE OF CONTENTS

SECTION PAGE
1 GENERAL INFORMATION 2
2 SAFETY GUIDELINES 5
3 OPERATION 7

3.1 How the Compressor Works 7

3.1.1 Components 7

3.1.2 Controls 8

3.1.3 Inlet Air System 8

3.1.4 Discharge System 9

3.2 Assembly 11

3.3 Pre-Operation Checklist 11

3.4 Break-in and Startup 12

3.5 Daily Starting Checklist 12
4 MAINTENANCE 13

4.1 Maintenance Safety 13

4.2 Servicing Intervals 13

4.3 Pump Lubricant 14

4.4 Pulley Alignment and Belt Tension 14

4.5 Bolt Torque Specifications 16
5 TROUBLESHOOTING 17
6 AIR COMPRESSOR SPECIFICATIONS 19
7 ASSEMBLY PART LISTS 22
8 PUMP PART LISTS 44

1

1. GENERAL INFORMATION

Congratulations on your choice of a Powerfist Compressor. This equipment has been designed and
manufactured to meet the light industrial and consumer needs of air compressors.

Safe, efficient and trouble free operation of your Compressor requires that you and anyone else who will be
operating and maintaining the machine, read and understand all of the safety, operation maintenance and
troubleshooting information contained within this Operator’s Manual.

WARRANTY- PARTS - SERVICE

If you experience any problems and need assistance or parts and repair service please contact Princess Auto
Ltd. at:

Telephone # [phone] Fax # [phone]

To obtain prompt, efficient service, always provide the serial number and item number of your unit. See the
parts list for location of the serial number decal. Please mark the numbers in the space provided for easy
reference.

SERIAL # ________________________

ITEM # ________________________

Printed in Canada 10002216-1
Issue Date: June 2010 Revision 12

2

IMPORTANT

The compressor tank is an ASME certified pressure vessel. The CRN and manufacturer’s information is
stamped on the tank nameplate. A certification document with the corresponding serial number is provided
with this manual for every compressor tank. Provincial jurisdictions require compressors to be registered with
Departments of Labour upon installation. Below is a list of Provincial jurisdictions that handle registration. It is
the customer’s responsibility to contact these offices and obtain registration.
Note: All registrations for Atlantic Provinces are handled by ACI Central P.E.I.

Technical Committee on Boilers & Pressure Vessels

Jurisdiction Chief Inspector/Contact

Ministry of Municipal Affairs
Safety Engineering Division
Design Survey Dept.
88 - 6th Street Suite 400
New Westminster, BC V3L 5B8

Alberta Boiler Safety Association
#200, 4208 – 97 Street
Edmonton, AB T6E 5Z9

Saskatchewan Municipal Services
Protection Services Branch
Boiler & Pressure Vessel Safety
330 – 1855 Victoria Ave.
Regina, SK S4P 3V7

Department of Labour & Manpower
Mechanical & Engineering
500 – 401 York Ave.
Winnipeg, MB R3C 0P8

Technical Standards Safety Authority
3300 Bloor Street West

th

Floor, West Tower

4
Etobicoke, ON M8X 2X4

Regie du Batiment du Quebec
Service de L’inspection de la Fabrication
d’appareils sous pression
545 Boul Cremazie est, 4 etage
Montreal, QC H2M 2V2

Department of Labour & Manpower
Technical Services Branch
PO Box 6000
Fredericton, NB E3B 5H1

Department of Labour
Boiler Inspection Branch
Box 2000, 68 University Avenue
Charlottetown, PEI E3B 5H1

Department of Labour & Manpower
Occupational Safety Division
5151 Terminal Road, 6th Floor
PO Box 697, Halifax, NS B3J 2T8

Government of Newfoundland & Labrador
Department of Government Services and Lands
5 Mews Place, PO Box 8700
St. John’s, NFLD A1B 4J6

ACI Central (for all registrations in NB, NS, PEI, NFLD)
20 McAulay Court, PO Box 53
Charlottetown, PEI C1A 9M7

S. Katz
Ph: [phone]
Fax: [phone]

K.T. Lau, Chair
B. McWhirter
Ph: [phone]
Fax: [phone]
N. Surtees
Ph: [phone]
Fax: [phone]

I.W. Mault
Ph: [phone]
Fax: [phone]

R. Mile
C. Turylo
Ph: [phone]
Fax: [phone]
R. Awad
M. Kotb
Ph: [phone]
Fax: [phone]

D.E. Ross

See ACI Central

K. Hynes

See ACI Central

Charles J. Castle
Ph: [phone]
Fax: [phone]

See ACI Central

D. Eastman
Ph: [phone]
Fax: [phone]

See ACI Central

Krista Cudmore
Ph: [phone]
Fax: [phone]

3

Jurisdiction Chief Inspector/Contact

Department of Municipal & Community Affairs
Protective Services
PO Box 2703, 2701 Second Ave.
Main Administration Building
Whitehorse, Yukon Y1A 2C6

Government of the Northwest Territories
Department of Public Services, Safety Division Boiler &
Pressure Vessel Branch
4916-49
Yellowknife, NWT X1A 2L9

Government of Nunavut
Public Works & Services
Kitikmeot region
Bag Service 200
Cambridge Bay, Nunavut X0B 0C0

th

Street, Northway Building

Dan Price

S. Donovan

B. Bachellier
Ph: [phone]

4

2. SAFETY GUIDELINES

DEFINITIONS

Safety symbols identify important safety messages that alert to the possibility of personal injury or death.
Review them carefully before operating the unit and before performing maintenance or repairs. Check the rules
and regulations at your location and identify possible hazards. The appropriate signal word for each message
has been selected using the following guidelines:

- Danger indicates an immediate and specific hazard, which will result in severe personal

injury or death if the proper precautions are not taken.

- Warning indicates a specific hazard or unsafe practice, which could result in severe

personal injury or death if proper precautions are not taken.

- Caution indicates a potentially hazardous situation, which may result in minor or moderate

injury if proper practices are not taken.

____________________________________________________________________________

IMPORTANT SAFETY INSTRUCTIONS

Read and understand the operator’s manual and all safety alerts before
operating or maintaining your Compressor. Be certain that everyone operating this
equipment is familiar with the recommended operating and maintenance procedures
and follows all the safety precautions. Never let children or untrained adults operate
the machine.

_______________________________________________________________________________

RISK OF FIRE OR EXPLOSION

Never spray flammable liquids in a confined area. It is normal for the motor and pressure switch to produce
sparks while operating. If sparks come into contact with vapors from gasoline or other flammable solvents,
they may ignite, causing a fire or an explosion. Always operate the compressor in a well-ventilated area as far
from spray area as possible.

RISK OF BURSTING

Air under pressure will cause injury, death or property damage. Do not exceed pressure rating. Safety relief
valve settings must not be changed, check regularly for proper operation. Do not weld, drill or modify
compressor tank; it can severely impair tank strength and cause extremely hazardous conditions. Any
adjustment by user will void the warranty.

RISK OF INJURY

Do not operate with belt guard removed. Wait for all moving parts to stop before removing belt guard for
compressor servicing. Belt guard must be fastened in place before starting the compressor.

RISK OF ELECTRICAL SHOCK

All electrical enclosures, cables, wiring and components must be installed and grounded in accordance with
national and local electrical code.

ALL WIRING MUST BE DONE BY A LICENSED ELECTRICIAN.

in personal injury or damaged components.

Failure to comply could result

5

2. SAFETY GUIDELINES

(cont’d)

RISK OF BURNS

High temperatures are generated by the operation of the compressor. Contact with hot surfaces, such as the
pump or discharge hose could result in a serious burn. Allow them to cool off before handling or servicing.
Keep children away from the compressor at all times.

RISK TO BREATHING

Toxic, volatile and corrosive vapors can cause personal injury. Provide adequate ventilation. Never directly
inhale compressed air produced by a compressor. It is not suitable for breathing purposes. Read all labels
when you are spraying paints or toxic chemicals and follow the safety instructions.

RISK OF HEARING AND EYE INJURY

Always wear hearing protection and approved safety goggles when using an air compressor. Failure to do so
may result in hearing loss and serious injury.

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3. OPERATION

3.1 HOW THE COMPRESSOR WORKS

3.1.1 COMPONENTS

The basic components of the air compressor are the electric motor, pump, tank and pressure switch. The
motor (item A) powers the pump. The motor drives a pulley and belt, which transfers power from the motor to
the pump pistons via a flywheel and a crankshaft. The flywheel fan helps cool the pump.

The pump (item B) compresses the air and discharges it into the tank. As the piston in the pump cylinder
moves downward, air enters the cylinder through the filter and air intake valves at atmospheric pressure. As
the piston moves upward, it compresses the air and discharges it into the tank through an unloader/check
valve.

The tank (item C) stores the compressed air. A check valve at the tank inlet prevents the compressed air in
the tank from flowing back into the pump.

The pressure switch (item D) shuts down the motor when the air pressure in the tank reaches the kick-out
pressure. As compressed air is used and the pressure level in the tank drops to the kick-in pressure, the
pressure switch restarts the motor automatically, without warning, and the pump resumes compressing air.

A Motor
B Pump
C Tank
D Pressure Switch
E Relief Valve
F Pressure Gauge
G Check Valve

G

F

E

B

A

D

Figure 1: Air Compressor Components

C

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3.1.2 CONTROLS

1. Check Valve

Check valves (item G in Figure 1, page 5) are designed to prevent backflow of air pressure in the
compressed air system (i.e. air flows freely in one direction only).

2. Pressure Relief Valves

The pressure relief valve (item E in Figure 1, page 5) aids in preventing system failures by relieving
pressure when compressed air reaches a determined level. They are available in various pressure
settings. Pressure relief valves are pre-set by the manufacturer and under no circumstances should
the setting be changed by anyone other than the manufacturer. All pressure relief valves must be
tested on a regular basis and kept clean by pulling the ring connector on the end of the valve.

3. Pressure Switch

The pressure switch detects the demand for compressed air and allows the motor to start. When the
system pressure reaches a set limit, the motor is shut off. Pressure switches provided, are pre-set at
the factory and should not be adjusted. WARNING! Never exceed the designed pressure for the

system or overload the motor beyond the amperage rating on the motor label.

3.1.3 INLET AIR SYSTEM

A clean, cool and dry air supply is essential to the satisfactory operation of your compressor. The standard air
filter that the compressor is equipped with when leaving the factory is of sufficient size and is designed to meet
normal conditions, when properly serviced in accordance with the maintenance section of this manual.

If however the compressor is to be installed in a location where considerable dust, dirt and other contaminants
are prevalent, consult your local Distributor for advice. It is the user’s responsibility to provide adequate
filtration for these conditions. Oil bath filters are not to be used.

CAUTION: Never locate the compressor where toxic, volatile or corrosive vapors, air temperatures
exceeding 100 degrees F, water, or extremely dirty air could be ingested. The performance of the

compressor system could be adversely affected.

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3.1.4 DISCHARGE SYSTEM

1. Discharge Pipe

The discharge piping should be of the same diameter as the compressor discharge connection, or
sized so that the pressure drop at any point in the system does not exceed 10% of the air receiver
pressure.

2. Auxiliary Air Receiver

Install auxiliary air receivers near heavy loads or at the far end of a long system. This will ensure
sufficient pressures if the use is intermittent, or sudden large demands are placed on the system.

3. Moisture Removal and Air Filtration

As the air cools, moisture will condense in the line. This moisture must be removed before it reaches
the tool being used. To remove this moisture, run the main air line downhill to a moisture trap and
drain. All service line outlets should be installed above the moisture trap to prevent moisture from
entering the tool or device used with the air.

4. Shut-off Valves

Install shut-off valves in each drop line to isolate the tool and its accessories for servicing. You can
also install a bypass line around an accessory.

5. Air Receiver Tank

An air receiver tank stores the compressed air. WARNING! Pressure vessels must not be
modified, welded, repaired, reworked or subjected to operating conditions outside the
nameplate ratings. Such actions may cause property damage, severe injury or even death.

6. Drain Valve

A drain valve must be located in the bottom of the air receiver tank to allow for moisture drainage.

7. Air Pressure Gauge

The air pressure gauge on the tank measures air pressure inside the tank. Install the air pressure
gauge in the drop line for each tool to regulate air pressure to the tool. Never exceed the maximum

pressure rating.

8. Air Lubrication

Install an air lubricator only for those tools requiring lubrication. DO NOT
spraying or similar applications.

use a lubricator for paint

9

10

Figure 2: Compressor Air System

3.2 ASSEMBLY

1. Unpack the air compressor. Inspect the unit for damage. If the unit has been damaged in transit
complete a damage claim.

2. Check the compressor’s item number to confirm you have received the model ordered.

3. Ensure that adequate lifting equipment is available for moving the compressor. Follow good shop
practices and safety procedures.

4. If necessary for your model install rubber feet provided in the kit.

CAUTION! The shipping pallet is not designed as a base for an operating compressor. Remove
the compressor from the pallet and place it on the floor or a hard, level surface. The compressor must
be level to ensure proper lubrication of the pump and good drainage of the moisture in the tank. We
recommend the use of rubber vibration pads under the feet for stationary units.

5. The flywheel side of the compressor must be at least 12 inches (31cm) from any wall or obstruction in
a clean, well-ventilated area to ensure sufficient air flow and cooling.

6. Connect discharge system components (not included) to the tank outlet.

7. IMPORTANT! All wiring information is stated on the electric motor and on the pressure switch, or
provided with the magnetic starter (sold separately). Princess Auto cannot, by law, provide the

customer with any additional wiring information.

3.3 PRE-OPERATION CHECKLIST

1. Remove all loose pieces and installation tools from the compressor and check for installation debris.

2. Unless otherwise specified, compressors are normally shipped without lubricant in the crankcase. Add
the correct amount of specified oil to the crankcase of the pump.

3. Check motor and compressor pulleys for alignment and tightness on shaft.

4. Manually rotate the compressor pulley several rotations to be sure there are no mechanical
interferences.

5. Check belt tension.

6. Check all pressure connections for tightness and leaks.

7. Make sure all pressure relief valves are correctly installed.

8. Be sure all guards are in place and securely mounted.

9. Check fuses, circuit breakers and thermal overloads for proper ratings.

10. Open all manual shutoff valves at and beyond the compressor discharge.

11. After all the above conditions have been satisfied, the unit can be connected to the proper power
source.

12. Jog the starter switch to check the rotational direction of the compressor. It should agree with the
rotation arrow embossed on the compressor pulley.

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