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

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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. 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 # 1-800-665-8685 Fax # 1-800-265-4212

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

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

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: (604) 660-6254 Fax: (604) 660-3460

K.T. Lau, Chair B. McWhirter Ph: (780) 437-9100 Fax: (780) 437-7787 N. Surtees Ph: (306) 787-4522 Fax: (306) 787-9273

I.W. Mault Ph: (204) 945-3373 Fax: (204) 948-2309

R. Mile C. Turylo Ph: (416) 325-2000 Fax: (416) 326-8248 R. Awad M. Kotb Ph: (514) 837-6459 Fax: (514) 837-6459

D.E. Ross

See ACI Central

K. Hynes

See ACI Central

Charles J. Castle Ph: (902) 424-7527 Fax: (902) 424-3239

See ACI Central

D. Eastman Ph: (709) 729-2747 Fax: (709) 729 2071

See ACI Central

Krista Cudmore Ph: (902) 566-3133 Fax: (902) 566-3133

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

Street, Northway Building

Dan Price

S. Donovan

B. Bachellier Ph: (867) 983-4152

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

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.

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

Figure 1: Air Compressor Components

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.

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

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.

3.4 BREAK-IN & START-UP

This instruction manual, as well as any instructions supplied by the manufacturers of supporting equipment, should be read and understood prior to starting the compressor. With the pre-operation checklist completed and satisfied proceed to start the compressor.

1. Check oil level in the crankcase. The oil level should be no lower than the center of the sight glass.

2. Check that the drain cock is open.

3. Start compressor and watch for excessive vibrations and/or strange noises. If either exists, stop the compressor. Refer to troubleshooting for help in determining the cause of such problems.

4. Manually activate safety relief valves by pulling ring or lever.

5. Run the compressor unloaded for 20 minutes to lubricate and break-in the internal parts.

6. Close the drain cock. Compressor will fill the tank to the cut out pressure.

7. Check the operation of controls and system pressure.

8. Observe compressor operation closely for the first hour and then frequently for the next 8 hours of operation.

9. After the first 8 hours of operation change the oil, check the belt tension and inspect the system for leaks.

WARNING! - 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.

3.5 DAILY STARTING CHECKLIST

Do not proceed until the Pre-Operation Checklist and Break-In & Start-Up sub-sections have been read and are thoroughly understood.

1. Check oil level in the crankcase of compressor pump. Ensure level is at the center of the sight glass.

2. Drain liquid from the air receiver and moisture trap.

3. Start compressor as per factory instructions.

4. Check system pressure.

5. Check all pressure relief valves for proper operation.

6. Check control system for proper operation.

4. MAINTENANCE

4.1 MAINTENANCE SAFETY

1. Turn off motor and relieve pressure before servicing

2. Open all manual drain valves within the area to be serviced.

3. Isolate the compressor from the compressed air supply by closing a manual shutoff valve upstream and downstream from the compressor. Display a sign in clear view at the shutoff valve stating that the compressor is being serviced.

4. Lock open a pressure relief valve within the pressurized system to allow the system to be completely de-pressurized. NEVER remove a plug to relieve the pressure!

5. Wait for the unit to cool before starting to service. Temperatures of 125F can burn skin. Some surface temperatures exceed 350F when the compressor is operating.

4.2 SERVICING INTERVALS

1. Before and / or After Use

a) Check pump oil level. b) Drain drop legs and traps in air distribution system. c) Manually operate the pressure relief valves. d) Give compressor an overall visual inspection and be sure safety guards are in place. e) Check for any unusual noise or vibration

Check for oil leaks

2. 50 Hours or Every Two-Weeks Service

a) Inspect the air filter for contamination. Replace the air filter often to ensure a clean air supply to

the compressor pump. b) Clean the cooling surfaces of the intercooler and compressor. c) Check the compressor for air leaks. d) Check the compressed air distribution system for leaks.

Inspect oil for contamination. Change more often under humid or dirty conditions.

3. Monthly to Quarterly (160 – 500 hours)

a) Check belt tension and pulley alignment. b) Change pump oil (more frequently in harsher environments). c) Tighten any loose bolts or sheave fasteners. Check the overall operation of the unit.

4. 6 Months (1000 hours)

a) Inspect compressor valves for leakage and/or carbon build-up.

4.3 PUMP LUBRICANT

1. Oil Level

Always operate the unit in a level position. Prior to start-up, check the sight glass to ensure the oil in the pump is at the required level. If the oil level is too low, remove the oil fill plug and add oil until the level is at the center of the sight glass. For approximate oil requirements, see pages 16-17. Do not overfill or under fill as it could damage the pump. CAUTION! The oil level in the pump crankcase

must be checked daily.

2. Oil Type

The correct lubricant is essential to the proper operation of your compressor. For single stage or 2stage compressors, use ISO 68, SAE 25 weight oil. This compressor oil is available at your local Princess Auto store. CAUTION! Do not use motor oil in the compressor pump.

3. Condensation

Water condensing in the crankcase can occur under certain humid conditions or light duty cycling. This water must be removed from the pump to prevent damage. Drain the oil and refill.

Condensation can be prevented by allowing the pump to reach its normal operating temperature by releasing air from the tank and allowing the pump to run, or by using more air, which will cause the pump to operate more frequently. CAUTION! A rise in the oil level and a milky color indicates that condensation is forming in the crankcase. This condensation must be drained immediately or the pump may be damaged.

4.4 PULLEY ALIGNMENT & BELT TENSION

Improper pulley alignment and belt tension are causes for motor overloading, excessive vibration and premature belt or bearing failure. To prevent this from happening, check the pulley alignment and belt tension on a regular basis.

Periodically, inspect both the motor and compressor pulleys for oil, grease, nicks or burrs. Clean or replace pulleys if necessary. Make sure the pulleys are securely fastened. Align the compressor pulley with motor. The drive belt grooves of both pulleys should be in line with each other. The compressor crankshaft must be parallel to the motor shaft.

WARNING! To avoid personal injury, always shut off main power disconnects for the compressor and relieve all air pressure from the system before performing any service on the air compressor.

1. Belt Tension

Proper belt tension and pulley alignment must be maintained for maximum drive efficiency and belt life. The correct tension exists if a deflection (see A in Figure 3 on the next page) of ½” (13 mm) occurs by placing 10 lb (4.4 kg) of force (see B in Figure 3 on the next page) midway between the motor pulley and the pump flywheel. This deflection can be adjusted by the following procedure. The pulley should be carefully aligned with the flywheel and all setscrews should be kept tight.

4.4 PULLEY ALIGNMENT & BELT TENSION (cont’d)

1/2” Deflection

10 Lbs Force

1. Belt Tension (cont’d)

Figure 3: Belt Tension

a) Remove the belt guard.

b) Loosen the motor mounting bolts.

c) Shift the motor to the point where the correct deflection exists.

d) Retighten the motor mounting bolts.

e) Check to ensure that the tension remained correct.

f) Reinstall the belt guard. All moving parts must be guarded.

2. Pulley Alignment

To check pulley alignment, remove the belt guard and place a straightedge (C in Figure 4 below) against the pump flywheel (D in Figure 4 below). Measure and record the distance from the straightedge to the edge of the drive belt (dimension E). Then measure the distance from the straightedge to the edge of the drive belt again as shown by dimensions F and G. Both distances should be the same as dimension E. If F or G is different from E, there is a misalignment that must be corrected before the compressor is run. To correct a pulley misalignment, use the following procedure.

a) Remove the belt guard.

b) Loosen the motor mounting bolts.

c) Loosen the setscrew on the motor pulley.

d) Align the motor pulley with the pump flywheel (E=F=G).

e) Retighten the motor pulley setscrew.

f) Adjust the proper belt tension.

g) Retighten the motor mounting bolts.

h) Reinstall the belt guard. All moving parts must be guarded.

Figure 4: Pulley Alignment

4.5 BOLT TORQUE SPECIFICATIONS

The table shown below gives the correct torque values for various bolts and cap screws. Tighten all bolts to the torque values specified unless otherwise noted. Periodically check the torque values of all fasteners using the table as a guide. Replace hardware with the same strength materials.

Bolt

Diameter (in)

N/m ft-lbs N/m ft-lbs N/m ft-lbs

1/4 8 6 12 9 17 12

5/16 13 10 25 19 36 27

3/8 27 20 45 33 63 45

7/16 41 30 72 53 100 75

1/2 61 45 110 80 155 115

9/16 95 70 155 115 220 165

5/8 128 95 215 160 305 220 3/4 225 165 390 290 540 400 7/8 230 170 570 420 880 650

1 345 225 850 630 1320 970

SAE Grade 2 SAE Grade 5 SAE Grade 8

5. TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Excessive motor current draw. Low voltage/motor overload. Check that power supply is adequate and that

compressor is on a dedicated circuit.

Compressor Stalls. Low voltage to motor.

Seized pump.

Low discharge pressure. Air leaks.

Restricted air intake.

Leaking valves.

Blown gaskets.

Worn piston rings or cylinder.

Defective pressure switch.

Drive belt slipping.

Defective pressure gauge.

Compressor pump knocking. Loose motor pulley or compressor

flywheel.

Low oil level in pump crankcase.

Excess carbon on valves on top of piston.

Worn connector rod at wrist pin end.

Oil in discharge air. Worn piston rings or cylinder.

Restricted air intake.

Oil level too high.

Overheating. Poor ventilation.

Dirty cooling surfaces.

Clogged intake system.

Inadequate lubrication.

Restricted air passages.

Pulley rotation wrong.

Excessive belt wear. Pulley out of alignment.

Improper belt tension.

Pulley wobbles.

Furnish adequate power.

Contact authorized service center. Tighten or replace leaking fittings or connections. Do not over-tighten.

Clean or replace air filter element(s).

Contact authorized service centre.

Adjust drive belt.

Replace gauge. Tighten pulley and flywheel. Check alignment.

Keep oil level full at all times.

Contact authorized service centre.

Clean or replace the air filter element(s).

Reduce to proper level. Use non-detergent oil. Relocate compressor to an area with cool, dry, well circulated air at least 12 in. from the nearest wall.

Clean all cooling surfaces thoroughly.

Clean/replace intake filter.

Check oil level.

Replace transfer tubes and/or unloader.

Check pulley rotation direction. Realign pulley with compressor flywheel.

Readjust.

Replace the pulley and check for a damaged crankshaft or flywheel.

PROBLEM CAUSE SOLUTION

Compressor won’t start in cold temperature.

Low pressure (75 psi) pressure relief valve opens. High pressure (225 psi) pressure relief valve opens. Motor hums but won’t turn. Low voltage to compressor.

Water in the crankcase. Condensation.

Excessive vibration. Loose pulley.

Excessive oil consumption. Defective breather valve.

Stops shortly after starting. Low voltage causing motor

Stops after running for a while. Compressor or starter overheating. Ventilate compressor room area or remove

Too much back pressure in tank.

No power.

Compressor too cold.

Using wrong grade oil.

Intake valve to high pressure cylinder is plugged. Check valve blocked. Clean or replace the check valve.

Compressor starting under pressure.

Pump or motor not secured.

Foundation or frame inadequate.

Compressor feet are not level.

Wrong grade oil.

Leaking oil seal.

Restricted intake.

overload.

Open drain cock when starting motor.

Check all power sources and circuit.

Move compressor to a warmer location.

Use ISO 1001 30W compressor oil in temperatures above 30F (-1C) and 10W oil below 30F (-1C). Contact authorized service centre.

Motor wired for wrong voltage.

Check head unloader valve system.

Change oil. Run compressor for longer period until it is hot, ensuring the discharge valve is open. Tighten pulley.

Tighten bolts.

Check mounting. Surface should be level and strong.

Level with shims. Check breather valve.

Use correct grade of compressor oil.

Replace oil seal.

Check intake system. See note.*

starter from compressor and mount on wall.

*NOTE – LOW VOLTAGE – Low voltage can cause a multitude of problems. The most common cause of low voltage is when the wire size (gauge) supplying power to the compressor is too small. The longer the run of wire, the larger the diameter must be to overcome the inherent voltage loss caused by the wire resistance. The supply voltage at the main panel could also be low as supplied by your local power company, or you may have too many other pieces of equipment running off the same line. Your local electrician should be contacted to evaluate and correct the problem according to the National Electrical Code.

6. AIR COMPRESSOR SPECIFICATIONS

Model # 5E-1-60V 5E-2-80V 10E-2-120H-3-230 10E-2-120H-1-230 10E-2-120H-3-575

Part # 8355182 8346645 8346652 8347767 8347783

Tank Capacity (Gal)

Rated (PSI) 175 200 200 200 200

CFM @ 100 PSI 18.5 18 35 35 35

@ 175 PSI 16 16.9 31 31 31

Tank Size

Diameter (in) 20 24 24 24 24

Height/Length (in) 48 48 69 69 69

Plate (in) 25x9x5 18x14x5.5 40x14x4.5 40x14x4.5 40x14x4.5

Pump Model

Compression Stage 1 2 2 2 2

Cylinder 3 2 4 4 4

Oil Required

center of sight glass)

(fill to

60 80 120 120 120

LPW6548ALHI LP205CT LP210CT LP210CT LP210CT

1.6 L 1.5 L 1.9 L 1.9 L 1.9 L

Motor

RPM 3450 1750 1750 1750 1750

Frame R56HZ 184T 215T 215T 215T

Ph 1 1 3 1 3

Volt 230 230 230/460 230/460 575

Amp 20 22 26.8/13.4 38/19 10.3

HP 5 5 10 10 10

Magnetic Starter Required

Pressure Switch Set 115-140 PSI 135-175 PSI 135-175 PSI 135-175 PSI 135-175 PSI

Range Min/Max 50-175 40-250 PSI 40-250 PSI 40-250 PSI 40-250 PSI

Differential 35/55 25/65 25/65 25/65 25/65

Check Valve Vertical Vertical Vertical Vertical Vertical

Max Pressure Rating 400 PSI 400 PSI 400 PSI 400 PSI 400 PSI

Weight (LBS) 300 554 935 888 935

ODP ODP ODP ODP ODP

No Yes Yes Yes Yes

7. ASSEMBLY PART LISTS

COMPRESSOR

5 HP 1 STAGE VERTICAL

MODEL #5E – 1 – 60V

ITEM #8355182

COMPRESSOR

5 HP 1 STAGE VERTICAL

MODEL #5E – 1 – 60V

ITEM #8355182

No. Item No. Description Qty

1 10005698 TANK AIR 60 GAL V. 175 PSI 1

9224656 MOTOR 5 HP 3450 RPM 230V 1 PH 1

10001977 COMPRESSOR HEAD 5 HP 1 STG 3 CYL LPW655 1

9229691 NUT HEX SERRATED FLANGE .312-18 UNC 8 9229683 BOLT HEX SRD FLANGE .312-18 UNC X 1.50 4 9235250 BOLT HEX SER. .312-18UNC X .75 LG 4 9801259 SCREW SET SKT .25-20 UNC 2 9252560 PULLEY AK51 X .876/.877 BORE 1

10002565 BELT V A54 1

9800236 BOLT HEX SERRATED FLANGE .250-20 UNC 4 9226341 NUT HEX SER FLANGE .250-20 UNC 4

10005811 WASHER FLAT .290 ID X 1.25 OD X .0625 4

1291715 NIPPLE HEX .375 NPTM 2 9225681 VALVE .375 NPTF B BODY SS BALL 1 9252511 HOSE DISCHARGE .50 ID X 30" LG 1 9330051 INSERT B COMP .25 X .125 NPTM 2 9255068 TUBE RD NYLON .25 OD X 16.00" LG 1

10002560 TAG BREAK-IN OIL 1

9232141 ELBOW .375 NPT STREET 1

9236548 CAP B. HEX .375 NPTF 1 10005772 DECAL PAL MANUFACTURING 1 10000808 DECAL WARNINGS COMPRESSORS 1

9161365 DECAL DRAIN WATER 1

9161308 DECAL MAINTENANCE COMPRESSORS 1

9160813 DECAL PAL SERIAL # 1 10001981 DECAL 60 GAL SPECIFICATIONS 1

9161340 DECAL ARROW 1

9161563 DECAL WARNING PRESSURE SWITCH 1

10005699-3 BELT GUARD CLIPS 4

10005699 BELT GUARD 2 PIECE 1 10004206 PRESSURE SWITCH 5 HP, 1 PH 230V 1

9234410 ELBOW B .25 NPT STREET 90 1

9252503 RELIEF VALVE 150/160 PSI PRE-SET 1 10005703 PLUG 1/4 COUNTERSUNK HEX HEAD 1 10005846 NIPPLE HEX S .25 NPT X 2.50 LG 1

9236084 GAUGE PRESSURE 0-300 PSI 1

430447 CHECK VALVE VERTICAL .50 NPTM 1

9336074 CONNECTOR B COMPRESSION .25 TUBE X .125 NPTM 1 10003283 ELBOW .50 NPTM X .50 JICM EXT. LG 1

COMPRESSOR

5 HP 2 STAGE VERTICAL

MODEL #5E – 2 – 80V

ITEM #8346645

COMPRESSOR

5 HP 2 STAGE VERTICAL

MODEL #5E – 2 – 80V

ITEM #8346645

No.

Item No. Description Qty

1 10005940 TANK AIR 80 GAL VER. 200 PSI 1 2 10002222 COMPRESSOR HEAD 5HP 2 STG 1 3 9236068 MOTOR 5 HP 1750 RPM 208-230V 1 PH 1 4 9254426 BRACKET BELT GUARD 5/11 HP COMPRESSOR 1 5 9236316 CHECK VALVE VERTICAL .75 MP 1 6 9238064 ELBOW B .75 NPTM X .75 SAE 1 7 9330085 ELBOW B. .75 NPTF X .75 SAE FLARE 1 8 9238056 HOSE DISCHARGE .75 ID X 20" LG 1

9 10002560 TAG BREAK-IN OIL 1 10 9237207 BUSHING SPLIT TAPERED 1.125" 1 11 9236100 PULLEY DOUBLE GROOVE 7.00 OD B BELT H BUSHINGS 1 12 9800228 BOLT HEX .250-20 UNC X 1.50 LG 2 13 1291756 NIPPLE HEX .75 NPT X .75 NPT 2 14 10005952 REDUCER S .75 MNPT X .5 FNPT 1 15 9310061 NIPPLE B .375 NPT X 4.50 LG 1 16 10005459 PLUG BRASS .125 NPT HEX HEAD 1 17 10005955 VALVE .75 NPTF B BODY SS BALL 1 18 9232141 ELBOW .375 NPT STREET 1 19 9236548 CAP B. HEX .375 NPTF 1 20 3860013 BELT B70 2 21 10005772 DECAL PAL MANUFACTURING 1 22 10000808 DECAL WARNINGS COMPRESSORS 1 23 9161308 DECAL MAINTENANCE INSTRUCTIONS 1 24 10001074 DECAL 80 GAL SPECIFICATIONS 1 25 9160813 DECAL PAL SERIAL # 1 26 10005941 BELT GUARD 80 GAL COMPR. 2 PIECE 1 27 9314824 NIPPLE HEX S .25 X .25 2 28 10005811 WASHER FLAT .290 ID X 1.25 OD X .0625 4 29 9800236 BOLT HEX SERRATED FLANGE .250-20 UNC X .75 LG 4 30 10005971 BOLT HEX SRD FLANGE .312-18 UNC X 2.00 4 31 9229691 NUT HEX SERRATED FLANGE .312-18 UNC 4 32 9239641 BOLT HEX SRD .375-16 UNC 1" LG 4 33 9236183 NUT HEX SER. .375-16 UNC 4 34 9161365 DECAL DRAIN WATER 1 35 9161340 DECAL ARROW 1 36 9161563 DECAL WARNING PRESSURE SWITCH 1 37 9226341 NUT HEX SER FLANGE .250-20 UNC 4 38 10002364 PRESSURE SWITCH 5 HP, 1 PH 230V 1 39 10005893 CROSS S .25 FNPT 1 40 10005947 ELBOW 45 DEG .250 SWIVEL FNPT X MNPT 1 41 9236084 GAUGE PRESSURE 0-300 PSI 1 42 9236118 RELIEF VALVE 200/210 PSI 1 43 10005699-3 1/4 TURN FASTENER 5

COMPRESSOR

10 HP 2 STAGE HORIZONTAL

MODEL #10E – 2 – 120H – 3 – 230

ITEM #8346652

COMPRESSOR

4 34

10 HP 2 STAGE HORIZONTAL

MODEL #10E – 2 – 120H – 3 – 230

ITEM #8346652

No. Item No. Description Qty

1 10005879 TANK AIR 120 GAL HOR. 200 PSI 1

10002332 COMPRESSOR HEAD 10 HP, LPCA 210A 2 STAGE 1

9238098 MOTOR 10 HP 1750 RPM 208-230/460V 3PH 1 9238163 HOSE DISCHARGE .75 ID X 30" LG 1

9336090 ADAPTOR B .75 NPTM X .75 SAE FLARE 1 10005892 ADAPTOR S 45 DEG .25 MNPT X .25 MNPT 1 10005893 CROSS S .25 FNPT 1

9236548 CAP B. HEX .375 NPTF 1 10005881 CHECK VALVE VERTICAL .75 NPTM X .75 JIC 1

9161340 DECAL ARROW 1

3850393 PULLEY DBL GROOVE 7.75 OD 1

9238155 BUSHING SPLIT TAPERED 1.375" 1

9235250 BOLT HEX SER. .312-18UNC X .75 LG 1

3860301 BELT V B80 2

9330077 ELBOW B. .375 NPT STREET 1

9224304 NIPPLE B .375 NPT X 6.00 LG 1

9236118 RELIEF VALVE 200/210 PSI 1 10005772 DECAL PAL MANUFACTURING 1 10000808 DECAL WARNING 1

9161365 DECAL DRAIN WATER 1

9161308 DECAL MAINTENANCE INSTRUCTION 1

9161563 DECAL WARNING PRESSURE SWITCH 1

9234410 ELBOW B .25 NPT STREET 90 1

9314824 NIPPLE HEX S .25 X .25 1 10002364 PRESSURE SWITCH 5 HP, 1 PH 230V 1

9236084 GAUGE PRESSURE 0-300 PSI 1

9800228 BOLT HEX .250-20 UNC X 1.50 LG 2

9239641 BOLT HEX SRD .375-16 UNC 1" LG 4

9236183 NUT HEX SER. .375-16 UNC 8

9251935 BOLT HEX SER. .375-16UNC X 2.00 LG 4

9160813 DECAL PAL SERIAL # 1 10005905 BELT GUARD 120 GAL COMPR. 1 10005929 BOLT HEX SERRATED FLANGE .250-20 UNC 1.00 LG

9226341 NUT HEX SER FLANGE .250-20 UNC 4 10005811 WASHER FLAT .290 ID X 1.25 OD X .0625 4 10001075 DECAL 120 GAL SPECIFICATIONS 1

10005905-2 BRACKET BELT GUARD 10 HP 1

COMPRESSOR

10 HP 2 STAGE HORIZONTAL

MODEL #10E – 2 – 120H – 1 – 230

ITEM #8347767

COMPRESSOR

4 24

10 HP 2 STAGE HORIZONTAL

MODEL #10E – 2 – 120H – 1 – 230

ITEM #8347767

No.

Item No. Description Qty

1 10005879 TANK AIR 120 GAL HOR. 200 PSI 1

10002332 COMPRESSOR HEAD 10 HP, LPCA 210A 2 STAGE 1 10000459 MOTOR 10 HP 1750 RPM 208-230V 1PH 1

9238163 HOSE DISCHARGE .75 ID X 30" LG 1

9336090 ADAPTOR B .75 NPTM X .75 SAE FLARE 1

9251935 BOLT HEX SER. .375-16UNC X 2.00 LG 4

9236183 NUT HEX SER. .375-16 UNC 8

9239641 BOLT HEX SRD .375-16 UNC 1" LG 4

9161563 DECAL WARNING PRESSURE SWITCH 1

3850393 PULLEY DBL GROOVE 7.75 OD 1

9238155 BUSHING SPLIT TAPERED 1.375" 1

9800228 BOLT HEX .250-20 UNC X 1.50 LG 2

3860301 BELT V B80 2

9161365 DECAL DRAIN WATER 1 10005772 DECAL PAL MANUFACTURING 1

9161340 DECAL ARROW 1

9224304 NIPPLE B .375 NPT X 6.00 LG 1

9330077 ELBOW B. .375 NPT STREET 1

9236548 CAP B. HEX .375 NPTF 1

9235250 BOLT HEX SER. .312-18UNC X .75 LG 1 10001075 DECAL 120 GAL SPECIFICATIONS 1 10005905 BELT GUARD 120 GAL COMPR. 1 10005929 BOLT HEX SERRATED FLANGE .250-20 UNC 1.00 LG

9226341 NUT HEX SER FLANGE .250-20 UNC 4 10005811 WASHER FLAT .290 ID X 1.25 OD X .0625 4 10000808 DECAL WARNING 1

9161308 DECAL MAINTENANCE INSTRUCTION 1 10005881 CHECK VALVE VERTICAL .75 NPTM X .75 JIC 1 10005893 CROSS S .25 FNPT 1 10005892 ADAPTOR S 45 DEG .25 MNPT X .25 MNPT 1

9314824 NIPPLE HEX S .25 X .25 1

9234410 ELBOW B .25 NPT STREET 90 1 10002364 PRESSURE SWITCH 5 HP, 1 PH 230V 1

9236118 RELIEF VALVE 200/210 PSI 1

9236084 GAUGE PRESSURE 0-300 PSI 1

9160813 DECAL PAL SERIAL # 1

10005905-2 BRACKET BELT GUARD 10 HP 1

COMPRESSOR

10 HP 2 STAGE HORIZONTAL

MODEL #10E – 2 – 120H – 3 – 575

ITEM #8347783

COMPRESSOR

10 HP 2 STAGE HORIZONTAL

MODEL #10E – 2 – 120H – 3 – 575

ITEM #8347783

No. Item No. Description Qty

1 10005879 TANK AIR 120 GAL HOR. 200 PSI 1

10002332 COMPRESSOR HEAD 10 HP, LPCA 210A 2 STAGE 1

9238189 MOTOR 10 HP 1750 RPM 575V 3PH 1 9238163 HOSE DISCHARGE .75 ID X 30" LG 1 9336090 ADAPTOR B .75 NPTM X .75 SAE FLARE 1 9251935 BOLT HEX SER. .375-16UNC X 2.00 LG 4 9236183 NUT HEX SER. .375-16 UNC 8 9239641 BOLT HEX SRD .375-16 UNC 1" LG 4 9161563 DECAL WARNING PRESSURE SWITCH 1 3850393 PULLEY DBL GROOVE 7.75 OD 1 9238155 BUSHING SPLIT TAPERED 1.375" 1 9800228 BOLT HEX .250-20 UNC X 1.50 LG 2 3860301 BELT V B80 2 9161365 DECAL DRAIN WATER 1

10005772 DECAL PAL MANUFACTURING 1

9161340 DECAL ARROW 1 9224304 NIPPLE B .375 NPT X 6.00 LG 1 9330077 ELBOW B. .375 NPT STREET 1 9236548 CAP B. HEX .375 NPTF 1 9235250 BOLT HEX SER. .312-18UNC X .75 LG 1

9160813 DECAL PAL SERIAL # 1 10005905 BELT GUARD 120 GAL COMPR. 1 10005929 BOLT HEX SERRATED FLANGE .250-20 UNC 1.00 LG 4

9226341 NUT HEX SER FLANGE .250-20 UNC 4 10005811 WASHER FLAT .290 ID X 1.25 OD X .0625 4 10001075 DECAL 120 GAL SPECIFICATIONS 1 10000808 DECAL WARNING 1

9161308 DECAL MAINTENANCE INSTRUCTION 1 10005881 CHECK VALVE VERTICAL .75 NPTM X .75 JIC 1 10005893 CROSS S .25 FNPT 1 10005892 ADAPTOR S 45 DEG .25 MNPT X .25 MNPT 1

9314824 NIPPLE HEX S .25 X .25 1

9234410 ELBOW B .25 NPT STREET 90 1 10002364 PRESSURE SWITCH 5 HP, 1 PH 230V 1

9236118 RELIEF VALVE 200/210 PSI 1

9236084 GAUGE PRESSURE 0-300 PSI 1

10005905-2 BRACKET BELT GUARD 10 HP 1