Pulsar PCE6150 Owners Manual

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Page 1

Table of Contents

Owner’s Manual

Topic

Safety Guidelines-Definitions 4

Hazard Warnings 5

Air Compressor

Precautions 15

Basic Air Compressor Components 16

Assembling the Air Compressor 16

Compressor Controls 18

Electrical Power Requirements 19

Breaking In The Pump 21

Operating Instructions 21

Maintenance 23

Storage 24

Service 24

Troubleshooting 25

Glossary Terms 29

Parts Listing 30

Page

Limited Warranty 35

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Air Compressor

Owner’s Manual

Warning! Read And Understand All Safety Precautions In This Manual Before Operating. Failure To Comply With Instructions In This Manual Could Result In Personal Injury, Property Damage, And / Or Voiding Of Your Warranty. Pulsar Products, Inc. Will Not Be Liable For Any Damage Because Of Failure To Follow These Instructions.

Air Compressor

Prior to installation and usage, thoroughly inspect air compressor for damages.  &KHFN WKH WDQN FRPSUHVVRU FRPSUHVVRU PRWRU DQG SXPS IRU DQy signs of damage or corrosion.

 &KHFN DOO VFUHZV EROWV QXWV DQG IDVWHQHUV FRQILUP WKDW WKHy are secure.  &RQILUP WKDW DOO ILWWLQJV WDQN SHWFRFN KDUGZDUH DQG SDLQW are free from rust

and corrosion.  &RQILUP WKDW DOO FRPSUHVVRU VHWWLQJV DUH FRUUHFW SULRU WR VWDrt up and usage.

Air Tool Inspection

Prior to connecting and using the compressor, thoroughly inspect each air tool for damage.

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are secure.

 &RQILUP WKDW DOO ILWWLQJV ELWV DQG KDUGZDUH DUH LQ JRRG FRQGition.  &RQILUP WKDW WKH WRRO VHWWLQJV DUH FRUUHFW SULRU WR FRQQHFWLRn an

d usage.

SAFETY GUIDELINES-DEFINITIONS This manual contains important information that you need to know and understand in order to protect YOUR SAFETY and to PREVENT EQUIPMENT PROBLEMS. The following symbols help you recognize this information. Please read the manual and pay attention to these sections.

WARNING! WARNINGS INDICATE A CERTAINTY OR

STRONG POSSIBILITY OF PERSONAL INJURY OR DEATH IF INSTRUCTIONS ARE NOT FOLLOWED.

CAUTION: CAUTIONS INDICATE A POSSIBILITY OF

EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT FOLLOWED.

NOTE: NOTES GIVE HELPFUL INFORMATION.

WARNING!

THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT. WHEN USING AIR TOOLS, BASIC SAFETY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO REDUCE THE RISK OF PERSONAL INJURY.

IMPROPER OPERATION OR MAINTENANCE OF

Save These Important Safety Instructions!

Read and understand all of these safety instructions. Be sure to retain them for future use.

Page 3

Air Compressor

Owner’s Manual

Hazard Warnings

Dust

WARNING! DUST FROM POWER SANDING, SAWING,

GRINDING, DRILLING, AND OTHER CONSTRUCTION ACTIVITIES CONTAIN CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. These chemicals may include (but are not limited to) the following:

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Bursting:

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warranty.

&KHFN WKH PDQXIDFWXUHU¶V PD[LPXP SUHVVXUH UDWLQJ IRU DLU WRROV and accessories. &RPSUHVVRU RXWOHW SUHVVXUH PXVW EH UHJXODWHG VR QRW WR H[FHHG WKH PD[LPXP SUHVVXUH UDWLQJ RI WKH WRRO 5HOLHYH DOO SUHVVXUH LQ WKH KRVH Eefore attaching or UHPRYLQJ DFFHVVRULHV 'R QRW WDPSHU ZLWK WKH SUHVVXUH VZLWFK RU UHOLHI YDOYH IRU DQ\ UHDVRQ 'RLQJ VR YRLGV DOO ZDUUDQWLHV 7KH\ KDYH EHHQ SUHVHW DW WKH IDFWRU\ IRU WKH PD[LPXP SUHVVXUH RI WKLV XQLW 3HUVRQDO LQMXU\ DQGRU SURSHUW\ GDPDJH PD\ UHVXOW LI WKH SUHVVXUH VZLWFK RU WKH UHOLHI YDOYH DUH WDPSHUHG ZLWK 'R QRW XVH SODVWLF RU 39& SLSH IRU FRPSUHVVHG DLU 8VH RQO\ JDOYDQL]HG VWHHO SLSH  ILWWLQJV IRU FRPSUHVVHG DLU GLVWULEXWLRQ OLQHV

Hazard Warnings (cont’d)

RISK OF EYE OR HEAD INJURY

What could happen:

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How to prevent it:

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Page 4

Air Compressor

Owner’s Manual

Hazard Warnings (cont’d)

RISK OF FIRE OR EXPLOSION

What could happen:

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Hazard Warnings (cont’d)

RISK OF HEARING LOSS

What could happen:

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SHUPDQHQW KHDULQJ ORVV

How to prevent:

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RISK TO BREATHING/INHALATION HAZARD

What could happen:

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SDLQWV RU WR[LF PDWHULDOV

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Air Compressor

Owner’s Manual

Hazard Warnings (cont’d)

RISK OF INJURY

What could happen:

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ZLWK PRYLQJ SDUWV

Hazard Warnings (cont’d)

RISK OF INJURY (cont’d)

How to prevent it:

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WKH UHDFK RI FKLOGUHQ DQGRU XQWUDLQHG XVHUV  8VH RQO\ SDUWV IDVWHQHUV DQG DFFHVVRULHV UHFRPPHQGHG E\ WKH PDQXIDFWXUHU  .HHS WKH ZRUN DUHD FOHDQ DQG IUHH RI FOXWWHU .HHS FKLOGUHQ DQG RWKHUV DZD\ IURP WKH DUHD

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\RX DUH WLUHG  1HYHU XVH WRROV ZKLFK KDYH EHHQ GURSSHG LPSDFWHG RU GDPDJHG

Page 6

Air Compressor

Owner’s Manual

Hazard Warnings (cont’d)

RISK OF INJURY (cont’d)

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Hazard Warnings (cont’d)

RISK OF ELECTRIC SHOCK

What could happen:

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GHDWK

How to prevent it:

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ZRUN

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ZLULQJ

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DV LW PD\ FDXVH DQ HOHFWULF VKRFN

Page 7

Air Compressor

Owner’s Manual

Hazard Warnings (cont’d)

RISK OF ENTANGLEMENT

What could happen:

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RWKHU ORRVH REMHFWV WKHUHE\ UHVXOWLQJ LQ LQMXU\

How to prevent it:

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Hazard Warnings (cont’d)

RISK OF CUT OR BURNS

What could happen:

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LQMXU\

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How to prevent it:

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Page 8

Air Compressor

Compressor Specifications

PCE6150

15Gallon/56.8L

120/13/1

WARNING! The power cord on this product contains

lead, a chemical, known to the state of California to cause cancer and birth defects or other reproductive harm. Wash your hands after handling

Precautions

 'UDLQ WKH PRLVWXUH IURP WKH WDQN EHIRUH HDFK XVH WR KHOS SUHYent corros

ion.

Owner’s Manual

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Operator manual and warranty card

Page 9

Air Compressor

Owner’s Manual

this

the

andfrom

also

Air Pressure Gauge

Air Pressure Regulator

Quick Connect Outlets

Moisture Release Valve

Page 10

Air Compressor

Owner’s Manual

Compressor (cont’d)

COMPRESSOR CONTROLS

Regulated pressure quick connect coupler: This coupler connects to the regulated outlet pressure valve. To connect the air hose, push the coupler in. To disconnect the air hose, pull the coupler collar back and separate the coupling.

Electrical Power Requirements Electrical Wiring

Refer to the air compressor’s registration label for the unit’s voltage and amperage requirements. Use a dedicated circuit. For best performance and reliable starting, the air compressor must be plugged into a dedicated circuit, as close as possible to the fuse box or circuit breaker. The compressor will use the full capacity of a typical 15 amp household circuit. If other devices are on the same circuit, the compressor may fail to start. Low voltage or an overloaded circuit can result in sluggish starting that causes the motor overload protection system circuit breaker to trip, especially in cold conditions.

Note: A circuit breaker is recommended. If the air compressor is connected to a circuit protected by a fuse, use a dual element time delay fuses (Buss Fusetron type“1”only).

Note: Avoid use of extension cords. If use of an extension cord is necessary, be sure to use an extension with the correct specifications. For optimum performance, plug the compressor power cord directly into a grounded wall socket. Do not use an extension cord unless absolutely necessary. Instead, use a longer air hose to reach the area where the air is needed. If use of an extension cord cannot be avoided, the cord should be no longer than 100 feet and be a minimum wire size of 14 gauge (AWG).

Compressor (cont’d)

ELECTRICAL POWER REQUIREMENTS (cont’d)

Extension Cord Use the chart on the right for the proper extension cord length.

Use only a 3-wire extension cord that has a 3-blade grounding plug and a 3-slot receptacle that will accept the plug of the product. Make sure your extension cord is in good condition. An undersized cord will

AMP

RATING

(120 Volts)

10 12

12 14

14 16

16 18

18 20

LENGTH OF

CORD IN FEET

25’

50’

100’

150’

cause a drop in line voltage as well as a loss of power and overheating. The smaller the gauge number, the heavier the cord.

Grounding Instructions

This product is equipped with a cord having a grounding wire and an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinance.

WARNING! IMPROPER INSTALLATION OF THE GROUNDING PLUG CAN RESULT IN THE RISK OF ELECTRIC SHOCK. IF REPAIR OR REPLACEMENT OF THE CORD OR PLUG IS NECESSARY, DO NOT CONNECT THE GROUNDING WIRE TO THE FLAT BLADE TERMINAL. THE WIRE INSULATION THAT HAS AN OUTER SURFACE THAT IS GREEN GREEN WITH, OR WITHOUT, YELLOW STRIPES IS THE GROUNDING WIRE.

This product is for use on a nominal 110 volt circuit. An outlet having the same configuration as the plug. No adapter should be used with this product. Do not alter the plug to fit into a non–Ground or 2-slot receptacle.

Page 11

Air Compressor

Owner’s Manual

Compressor (cont’d)

BREAKING IN THE PUMP

1.Turn the switch to the OFF position.

2. Open the petcock. Turn counterclockwise (loosen).

3. Plug in the power switch to the ON position.

4. The compressor will start.

ALLOW THE COMPRESSOR TO RUN FOR 15 MINUTES, TO BREAK IN THE INTERNAL PARTS.

CAUTION: AFTER ABOUT 15 MINUTES. IF THE UNIT DOES NOT

OPERATE PROPERLY, SHUT IT DOWN IMMEDIATELY AND CONTACT THE PRODUCT SERVICE CENTER 1-866-591-8921.

5. After about 15 minutes, turn the power switch to the OFF position.

6. Close the petcock. Turn in the clockwise direction.

7. Turn the power switch to the ON position. The compressor will start and fill the tank to the kick-out pressure and stop.

Note: As compressed air is used, the pressure switch will restart the motor automatically.

Compressor (cont’d)

OPERATING INSTRUCTIONS

WARNING! HIGH TEMPERATURES ARE GENERATED BY THE

ELECTRIC MOTOR AND THE PUMP. TO PREVENT BURNS OR OTHER NJURIES, I DO NOT TOUCH THE COMPRESSOR WHILE IT IS RUNNING. ALLOW IT TO COOL I BEFORE HANDLING OR SERVICING. KEEP CHILDREN AWAY FROM THE COMPRESSOR AT ALL TIMES.

WARNING! WHEN ADJUSTING FROM A HIGHER TO A LOWER

PRESSURE, TURN THE KNOB COUNTERCLOCKWISE TO REACH THE DESIRED PRESSURE. DO NOT EXCEED THE OPERATING PRESSURE OF THE TOOL OR ACCESSORY BEING USED.

5. Adjust the regulator to the working pressure of the tool. (never exceed 90 PSI)

Shut down

1. Turn the power switch to the OFF position.

2. Unplug the power cord.

3. Reduce pressure in the tank thorough the outlet hose. You can also pull the relief valve ring and keep it open in the tank.

Note: During the initial break-in cycle, there will be a slight electrical smell as the motor brushes seat.This is normal for universal motors and will last for about 5 minutes.

OPERATING INSTRUCTIONS

Periodic Starting

1. Turn the power switch to the OFF position.

2. Close the tank petcock. Turn in the clockwise direction.

3. Plug in the power cord.

WARNING! ESCAPING AIR AND MOISTURE CAN PROPEL DEBRIS

THAT MAY CAUSE EYE INJURY. WEAR SAFETY GOGGLES WHEN OPENING PETCOCK.

4. Tip the compressor (if necessary for your model ) so the petcock is at the bottom of the tank(s).Then open the petcock to allow moisture to drain from the tank.

Page 12

Air Compressor

Owner’s Manual

after each use

Page 13

Air Compressor

Owner’s Manual

Compressor (cont’d)

TROUBLE SHOOTING

Note: Trouble shooting problems may have similar causes and solutions.

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Compressor (cont’d)

TROUBLE SHOOTING (cont’d)

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Page 14

Air Compressor

Owner’s Manual

Compressor (cont’d)

TROUBLE SHOOTING (cont’d)

Overheating

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Compressor (cont’d)

TROUBLE SHOOTING (cont’d)

Motor will not run (cont’d)

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Page 15

Air Compressor

Owner’s Manual

Compressor (cont’d)

TROUBLE SHOOTING (cont’d)

Glossary of Terms

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PARTS LISTING

24 25

Page 16

Air Compressor

Owner’s Manual

PARTS LISTING

PARTS NO. DESCRIPTION QTY.

PCE6150-M-01

PCE6150-M-02

PCE6150-M-03

PCE6150-M-04

PCE6150-M-05

PCE6150-M-06

PCE6150-M-07

PCE6150-M-08

PCE6150-M-09

PCE6150-M-10

PCE6150-M-11

PCE6150-M-12

PCE6150-M-13

PCE6150-M-14

PCE6150-M-15

PCE6150-M-16

PCE6150-M-17

PCE6150-M-18

PCE6150-M-19

PCE6150-M-20

PCE6150-M-21

PCE6150-M-22

PCE6150-M-23

PCE6150-M-24

PCE6150-M-25

PCE6150-M-26

PCE6150-M-27

PCE6150-M-28

PCE6150-M-29

PCE6150-M-30

PCE6150-M-31

PCE6150-M-32

PCE6150-M-33

PCE6150-M-34

PCE6150-M-35

SCREW

WASHER

TWO WAY PIPE

CYLINDER COVER

FILTER

CYLINDER COVER GASKET

BOLT

WASHER

VALVE BAFFLE

VALVE

VALVE PLATE

UPPER CYLINDER GASKET

LOCATING PIN

CYLINDER

LOWER CYLINDER GASKET

PISTON RING

SCRAPING OIL RING

PISTON

PISTON PIN

PISTON PIN CLIPS

PROTECTOR

BREATHER

BOLT

WASHER 6

WASHER

OIL GAUGE

OIL GAUGE SEAL

FRONT COVER

RUBBER WASHER CONNECTING ROD

CRANKSHAFT

OIL DISCHARGE SCREW

RUBBER WASHER

PARTS LISTING

PARTS NO. DESCRIPTION QTY.

PCE6150-M-36

PCE6150-M-37

PCE6150-M-38

PCE6150-M-39

PCE6150-M-40

PCE6150-M-41

PCE6150-M-42

PCE6150-M-43

PCE6150-M-44

PCE6150-M-45

PCE6150-M-46

PCE6150-M-47

PCE6150-M-48

PCE6150-M-49

PCE6150-M-50

PCE6150-M-51

PCE6150-M-52

PCE6150-M-53

PCE6150-M-54

PCE6150-M-55

PCE6150-M-56

CRANKCASE

BOLT

WASHER

NUT

WASHER

CAPACITOR

OIL SEAL

BEARING

ROTOR

BEARING

BACK COVER

FAN WHEEL

WASHER

SCREW

WASHER

ROTOR CLIPS 1

STATOR

CABLE

RADIATING COVER 1

Page 17

Owner’s Manual

PARTS LISTING

18 19 20

PARTS LISTING

PARTS NO. DESCRIPTION QTY.

PCE6150-A-01

PCE6150-A-02

PCE6150-A-03

PCE6150-A-04

PCE6150-A-05

PCE6150-A-06

PCE6150-A-07

PCE6150-A-08

PCE6150-A-09

PCE6150-A-10

PCE6150-A-11

PCE6150-A-12

PCE6150-A-13

PCE6150-A-14

PCE6150-A-15

PCE6150-A-16

PCE6150-A-17

PCE6150-A-18

PCE6150-A-19

PCE6150-A-20

PCE6150-A-21

PCE6150-A-22

PCE6150-A-23

PCE6150-A-24

PCE6150-A-25

MOTOR

BOLT

WASHER

NUT

TANK

NUT

WASHER

QUICK COUPLING

WASHER

POWER CORD

PRESSURE SWITCH

PRESSURE GAUGE

RELEASE PIPE

SAFETY VALVE

HANDLE SET

BOLT

WASHER

WHEEL

DISCHARGE VALVE

RUBBER FOOT

SCREW

CHECK VALVE 1

1DISCHARGE PIPE

1BRACKET

2WASHER

Page 18

Air Compressor

Owner’s Manual

LIMITED WARRANTY

Pulsar Products, Inc. warrants to the original purchaser who uses the product in a consumer application (personal, residential or household usage) that all products covered under this warranty are free from defects in material and workmanship for one year from the date of purchase. All products covered by this limited warranty which are used in commercial applications (i.e. income producing) are warranted to be free of defects in material and workmanship for 90 days from the date of original purchase. Products covered under this warranty include air compressors, air tools, service parts, pressure washers and generators. Pulsar Products, Inc will repair or replace at Pulsar Products, Inc. sole option, products or components which have failed within the warranty period. Service will be scheduled according to the normal work flow and business hours at the service center location, and the availability of replacement parts. All decisions of limited warranty shall be final. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

RESPONSIBILITY OF ORIGINAL PURCHASER (Initial User): To process a warranty claim on this product, DO NOT return item to the retailer. The product must be evaluated by an Authorized Warranty Service Center. For the location of the nearest Authorized Warranty Service Center contact the retailer or place of purchase. Retain original cash register sales receipt as proof of purchase for warranty work. Use reasonable care in the operation and maintenance of the product as described in the Owner’s Manual(s). Deliver or ship the product to the nearest Authorized Warranty Service Center. Freight costs, if any, must be paid by the purchaser. Air compressors with 60 and 80 gallon tanks will be inspected at the site of installation. Contact the nearest Authorized Warranty Service Center that provides on-site service calls for service call arrangements. If the purchaser does not receive satisfactory results from the Authorized Warranty Service Center, the purchaser should contact Pulsar Products, Inc..

Pulsar Products, Inc. with regard to this

LIMITED WARRANTY (cont’d)

THIS WARRANTY DOES NOT COVER: Merchandise sold as reconditioned, used as rental equipment, or floor or display models. Merchandise that has become damaged or inoperative because of ordinary wear, misuse, cold, heat, rain, excessive humidity, freeze damage, use of improper chemicals, negligence, accident, failure to operate the product in accordance with the instructions provided in the Owner’s Manual(s) supplied with the product, improper maintenance, the use of accessories or attachments not recommended by Pulsar Products, Inc., or unauthorized repair or alterations. Repair and transportation costs of merchandise determined not to be defective. Costs associated with assembly, required oil, adjustments or other installation and start-up costs. Expendable parts or accessories supplied with the product which are expected to become inoperative or unusable after a reasonable period of use. Merchandise sold by Pulsar Products, Inc. which has been manufactured by and identified as the product of another company, such as gasoline engines. The product manufacturer's warranty, if any, will apply. ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECTS, FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT COVERED BY THIS WARRANTY. Some states do not allow the exclusion, so it may not apply to you. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply.