W
STATIONARY
AIR COMPRESSOR
MANUAL
INSTALLATION ~ OPERATION ~ MAINTENANCE
Make a permanent record of the model and serial number of your new air compressor here. You’ll save time and
expense by including this reference information when requesting service or replacement parts.
COMPRESSOR DISCHARGE AIR MAY CONTAIN HYDROCARBON
AND OTHER CONTAMINANTS; THEREFORE, DO NOT USE
DISCHARGE AIR FOR BREATHING.
RECORD OF PERTINENT INFORMATION
Place & Date of Purchase Volts
Model Hz
Serial # HP
ARNING
With shut-off valve to outside line(s) closed and tank pressure at 0 PSI, record the amount of time it takes to build tank
pressure in the space provided below. Periodically test your compressor against this pump-up time to determine if it is
operating correctly. If time test is considerably off, contact your local ROLAIR representative to arrange service.
From 0 to _____PSI From 0 to _____PSI
Date Min. Sec. Date Min. Sec.
RECEIVING INSTRUCTIONS
CONGRATULATIONS ON THE PURCHASE OF YOUR NEW ROLAIR COMPRESSOR!
Immediately upon receipt of your air compressor and prior to completely uncrating, the following steps should be taken:
Step 1) Remove box and inspect compressor for damage that may have occurred during shipment. If any damage is
found, demand an inspection from the carrier. Ask the carrier how to file a claim for shipping damages. Freight
damage is not covered by ROLAIR warranty.
Step 2) Insure that adequate lifting equipment is available for moving the air compressor.
Step 3) Record the model number and serial number from the unit nameplate on the front of your owner’s manual. Space
is also provided for pump-up time test to be performed and recorded upon initial start-up of air compressor.
606 South Lake Street > P.O. Box 346 > Hustisford, WI 53034-0346 > 920.349.3281 > fax 920.349.3691 > www.rolair.com
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
WARNING
SAFETY WARNINGS
READ AND UNDERSTAND ALL SAFETY WARNINGS BEFORE USING AIR COMPRESSOR
Hazard Level Potential of Hazard How to Avoid Hazard
Risk of Asphyxiation
Risk of Bursting
Risk of Electrocution or
Electrical Shock
Risk of Explosion or Fire
Serious injury or death may occur from inhaling
compressed air. The air stream may contain
carbon monoxide, toxic vapors, or solid
particles.
Sprayed materials such as paint, stucco,
insecticides, solvents, etc. contain harmful
vapors and poisons that may cause serious
injury or death if inhaled.
Serious injury or death may occur if the
exhaust from gas-powered small engines is
inhaled. Engine exhaust fumes contain
poisonous, carbon monoxide which is odorless
and colorless.
Serious injury or death may occur from an air
tank explosion if the air tanks are not properly
maintained or if modifications, alterations or
repairs are attempted to the air receivers.
Serious injury or death may occur if
modifications are made to the pilot unloader
valve, pressure switch, safety relief valve or
other components that control the tank
pressure.
Serious injury may occur if accessories or
attachments are operated above the
manufacturer’s recommended pressure
ratings, causing them to explode or fly apart.
Serious injury or death could occur if the air
compressor is not properly grounded.
Electrical shock may occur if compressor is not
properly operated.
Serious injury or death may occur if electrical
repairs are attempted by unqualified personnel.
Serious injury or death may result from normal
electrical sparks that occur within the motor
and/or pressure switch.
Serious injury may occur if a fire is caused by
overheating due to inadequate ventilation or
restrictions to any of the compressors
ventilation openings.
Serious injury or death may occur from a fire or
explosion if spilled gas or vapors come in
contact with hot engine parts and ignite.
Never inhale compressed air directly from the
pump, receiver, or from a breathing device
connected to the air compressor.
Operate compressor only in a well-ventilated
area. Use a respirator device and follow the
manufacturer’s recommendations for their
spray equipment. Keep compressor at least 25
feet away from spray equipment.
Operate gas-powered compressors only in a
well-ventilated area. Avoid inhaling engine
exhaust fumes, and never run a small gaspowered engine in a closed building or
confined area without adequate ventilation.
Drain air tanks daily or after each use. Never
drill into, weld, patch or modify the air tanks. If
a leak develops, replace the tank immediately
or replace the entire compressor.
Never make adjustments to the components
that control tank pressure. Do not make
alterations to the factory operating pressure
settings. Check operation of the safety valve
on a regular basis and never operate without a
factory approved safety valve.
Do not use air tools or attachments before
reading the owner’s manual to determine the
maximum pressure recommendations. Never
exceed the manufacturer’s maximum
allowable pressure ratings. Do not use
compressor to inflate small low pressure
objects such as toys.
Always plug compressor into a properly
grounded outlet which provides correct
voltage, proper grounding and adequate fuse
protection.
Never operate air compressor in wet
conditions or outdoors when it’s raining. Do
not allow electric cords to lay in water. Do not
operate with damaged power cord or with
protective electrical covers removed. Do not
touch plug with wet hands. Do not pull on
electric cord to disconnect from the outlet.
Any electrical repairs or wiring performed on
this compressor should only be performed by
authorized service personnel in accordance
with the National and Local Electric Codes.
Always operate compressor in a well-ventilated
area free of combustible materials, gasoline,
flammable solvents or vapors. Always locate
compressor at least 20 feet away from work
area if spraying flammable materials.
Never place objects against or on top of an air
compressor. Always operate air compressor at
least 18” away from any wall or obstruction.
Always operate in a clean, dry and wellventilated area.
Never attempt to fill the gas tank while the
engine is hot or running. Add fuel outdoors in
a well-ventilated area. Do not fill gas tank near
lit cigarettes or near other sources of ignition.
Risk from Moving Parts
SAFETY WARNINGS (con’t)
Serious injury may occur from moving parts
such as belts, pulleys, flywheels or fans if they
came in contact with you or your clothing.
An electric air compressor with automatic
controls can restart at any time and cause
bodily injury when least expected.
Serious injury may occur if repairs are
attempted with damaged, missing or removed
protective guards, shrouds or missing covers.
Never operate the air compressor without
protective belt guards installed. Replace
damaged protective covers or guards
immediately.
Always unplug air compressor and drain air
tanks completely before attempting any repairs
or performing maintenance. Never allow
children or adolescents to operate air
compressor.
All repairs to the air compressor should be
made only by authorized or trained service
personnel.
Risk of Burn
Risk of Injury from Lifting
Flying Objects
Warning
Risk of Unsafe Operation
Caution
Risk of Damage to
Air Compressor or Property
Serious burn injuries could occur from touching
exposed metal parts such as the compressor
head, copper/braided discharge lines and
engine exhaust muffler during operation, and
even after compressor is shut down for
sometime.
Serious injury can result from attempting to lift
an object that is too heavy.
Serious injury may occur from loose debris
being propelled at high speeds from the
compressed air stream.
Serious injury or death may occur to you or
others if air compressor is used in an unsafe
manner.
Failure to transport or operate the air
compressor properly may result in major repair
expenses. Oil leaks will damage carpets,
painted surfaces, flooring and other items.
Never touch any of the exposed metal parts
during operation and for an extended period of
time after the air compressor has shut down.
Do not attempt maintenance on the unit until it
has been allowed to completely cool.
Always obtain assistance from others before
attempting to lift any object that is too heavy
for one person.
Always wear OSHA required “287” safety
glasses to protect the eyes during operation of
the air compressor. Never point the air stream
or tools at any point of your body, other people
or animals. Always turn off the air compressor
and drain tank pressure completely before
attempting maintenance or attaching air tools.
Review and understand all instructions and
warnings in your owner’s manual. Know how
to stop the air compressor. Do not operate
until you are thoroughly familiar with all of the
controls. Do not operate the compressor if
fatigued or under the influence of alcohol or
drugs. Stay alert while operating the
compressor and pay close attention to the task
at hand.
Check oil levels daily and maintain proper oil
levels. Always run compressor in a level,
secure position that keeps it from tipping or
falling during use. Do not operate without an
air filter or in a corrosive environment. Always
transport in a level position and use protective
mats to keep truck beds clean, etc. Check
drain bolts regularly and do not overfill
machinery with oil.
Please note that this product may not be equipped with a spark arresting muffler. If the compressor is operated around
flammable materials or agricultural crops, brush, forests, and grasslands an approved spark arrestor must be installed,
maintained and in good working order. An approved spark arrestor is legally required in the State of California under
sections 4442 and 4443 of the California Public Resources Code Statute section 130050.
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, and other
reproductive harm. Always wash hands after handling this product.
Periodic inspection of in-service pressure-retaining items is mandated in your jurisdiction. In addition to performing these
inspections, your jurisdiction may require or permit insurance companies to provide the mandated inspection service for
their insured. Information for your jurisdiction can be found on the National Board of Boiler and Pressure Vessel
Inspectors website by typing www.nationalboard.org/NationalBoard/Members/ in your web browser.
IMPORTANT
INSTALLATION
LOCATION:
• Locate the compressor in a cool, dry, clean and well-ventilated area with a temperature range between 35° and
105°F. WARNING! Under no circumstances should the air compressor be installed in an area that may be
exposed to a dirty, corrosive atmosphere, toxic vapors or volatile fumes. Do not store toxic, volatile or corrosive
agents near the compressor.
• The intake filter may be remotely located. Enlarge size of intake piping by 1/4” in size for each 10 feet of length.
• Install so that the flywheel/belt guard is at least 18” from an adjacent wall. Allow space on all sides for air
circulation and ease of maintenance.
• Make sure the compressor tank is mounted level on a solid foundation using vibration dampening pads made of
felt/rubber. If vibration pads cannot be located, the skid on which the compressor is shipped may be left on and
used as a mounting base. Solid shims may be used to level unit before bolting or lagging unit to prevent
movement.
NOTE: Contact your local ROLAIR representative for information on level-rite mounting pads or if excessive vibration
or movement is noticed upon initial test run. When hard-mounting a gas-powered air compressor on a trailer or a
truck bed, leave one of the four mounting bolts looser than the others (slightly beyond hand-tight) to help minimize
vibration and improve the overall performance and life of the unit.
ELECTRICAL CONNECTIONS AND MOTOR WIRING:
Most stationary ROLAIR compressors are shipped without a power cord. All power cords attached to this machine
must be properly grounded and installed by a qualified electrician with knowledge of the National Electrical Code
(N.E.C.), OSHA Code and/or any local/state/provincial codes having precedence. Failure to abide by applicable
electrical codes may result in personal injury or property damage.
Check the electrical supply for voltage, phase and frequency to see that they match the nameplate stampings on the
motor, magnetic starter, solenoids and other controls. Use electrical wires of adequate size to carry the full load
current of the motor without excessive voltage drop.
NOTE: Do not use a generator as the power source. Air compressors use inductive motors that require 3-5 times
the full-load amp draw to properly start. Most generators will not provide the wattage needed to properly start
this type of electric motor.
The motor must always be protected by a starter with properly sized thermal overload(s). The starter should protect
the motor from overheating and burn-out due to an overload, low voltage or single phasing of a 3-phase circuit. Failure
to install the proper starter and overloads will void the motor manufacturer’s warranty. Follow the National Electric
Code or local electric code in providing wiring, fusing and disconnect switches.
After the wiring is completed, momentarily start the motor to make certain that the compressor flywheel rotates in the
same direction as indicated by the direction arrow on the compressor flywheel.
NOTE: An easy way to check for proper rotation is to place a piece of paper on the outside of the belt guard
cover while the machine is running. If the piece of paper is blown away, the rotation is incorrect. Consult a
qualified electrician to correct the rotation. Improper rotation will lead to overheating and oil blowing out of the
crankcase breather.
PIPING FIT-UP:
Always position air compressor to avoid an excessive amount of tension between the external air lines and connection
at the air tank. The piping should be lined up without having to spring or twist it into position. Adequate expansion
loops or bends should be installed to prevent undue stresses at the compressor resulting from the changes between
hot and cold conditions. Pipe supports should be mounted independently of the compressor and anchored as
necessary to limit vibration and prevent expansion strains.
*Never join pipes or fittings with lead-tin soldering. Welded or threaded steel pipes and cast-iron fittings, designed for
the pressures and temperatures, are recommended. Never use PVC or plastic pipe.
Pipe sizes for compressed air lines
Air
CFM
1-5 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2
10 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4
15 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4
25 3/4 3/4 3/4 3/4 3/4 1 1 1
30 3/4 3/4 3/4 3/4 1 1 1 1
35 3/4 3/4 1 1 1 1 1 1
40 3/4 1 1 1 1 1 1 1
60-70 1 1 1 1 1-1/4 1-1/4 1-1/4 1-1/4
80-100 1-1/4 1-1/4 1-1/4 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2
25 50 75 100 150 200 250 300
Check all piping and fittings regularly to avoid leaks in the system.
Length of Pipe Lines in Feet
INSTALLATION
A
V
S
(con’t)
PIPING:
The compressed air distribution system should be of sufficient pipe size to keep the pressure drop between the
supply and point of use to a minimum. All piping should be sloped to an accessible drain-point. Outlets should be
taken from top of mainline so that moisture will not enter the outlet.
OPERATION
LUBRICATION:
Prior to daily operation, make a habit of checking the oil level in your compressor pump. A sight gauge on the outside
of the pump’s crankcase is provided to make the job easier. Always maintain the oil level to read 2/3 full on the sight
gauge. Oil levels over this amount will result in oil blowing past the rings or out of the crankcase breather. Lower
amounts of oil will result in insufficient lubrication of moving parts.
Reciprocating compressors will consume a certain amount of oil under normal operation. If you are concerned about
your oil consumption, monitor and record oil consumption daily and consult your local dealer. When filling your
crankcase with oil, be sure to use a single viscosity, non-detergent oil. DO NOT USE A
Oil Capacity
(oz.)
K8 12
K11 17
K12 15
K17 34
K18 34
K22 61
K23 61
K24 61
K25 61
K28 61
K30 47
K35 47
K50 59
K60 98
K70 98
K100 127
using ROLAIR Premium Quality compressor oil. (See your oil distributor
or representative for compressor oil.)
DO NOT USE DETERGENT OIL!
See chart for oil recommendation in varying temperature conditions.
DETERGENT OIL!!
Check the oil before starting.
Prior to shipping, complete units are filled with oil and tested. The oil should
be drained and replaced after an initial break-in period of 50 hours.
NOTE: Bare pumps are shipped without oil. See reference charts for oil type
and capacity.
Whether you have purchased a complete unit or bare
pump, check the oil level and correct if needed before
starting each day.
Important: Do not over-fill your pump. It will cause harm.
After break-in period, use a single-grade, non-detergent
motor oil with foam, rust and oxidation inhibitors. For
maximum performance and service life, we recommend
mbient
Temperature
0° - 40° 250-350 46-68 20
40° - 80° 450-550 100 30
80° - 120° 650-750 150 40
Under 0° Consult Factory
Over 120° Consult Factory
Proper Oil Level:
iscosity
@100°F
SSU
ISO
Viscosity
CS+
AE
No.
SYSTEM COMPONENTS
fficiency and safety are the primary concerns when selecting components for compressed air systems. Products of inferior quality
E
can not only hinder the performance of the unit, but could cause system failures or bodily harm. Select only top quality components
for your system. Call your local ROLAIR distributor for quality parts and professional advice.
DRIVE PULLEYS: Drive pulleys must be properly aligned and drive-belt
tension set to specifications. Improper pulley alignment and belt tension
can cause motor overloading, excessive vibration and premature belt
and/or bearing failure.
GUARDS: All mechanical action or motion is hazardous in varying
degrees and needs to be guarded. Guards should be designed to
achieve the required degree of protection and still allow full air flow
from the compressor flywheel across the unit. Guards shall be in
compliance with O.S.H.A. safety and health standards and any state or
local codes. When the compressor is installed, make sure guard side is at least 18” away from the wall to provide adequate cooling
of motor and pump.
CHECK VALVES: Check valves are designed to prevent back-flow of air pressure in the compressed air system (air flows freely in
one direction only.) The check valve must be properly sized for air flow and temperature. Do not rely upon a check valve to isolate a
compressor from a pressurized tank or compressed air delivery system during maintenance procedures!
MANUAL SHUT-OFF VALVES: Manual shut-off valves block the flow of air pressure in either direction. This type of valve can be
used to isolate a compressor from a pressurized system, provided the system is equipped with a safety-relief valve capable of being
manually released. The safety-relief valve should be installed between the manual shut-off valve and the compressor.
SAFETY-RELIEF VALVES: Safety-relief valves aid in preventing system failures by relieving system pressure when compressed air
reaches a determined level. A check valve and safety relief valve are required in all compressed air systems. Safety-relief valves are
pre-set by the manufacturer and under no circumstances should the setting be changed.
PRESSURE SWITCHES: The pressure switch detects the demand for compressed air and allows the motor to start. When the
demand is satisfied, the unit stops and unloads the head pressure with a short hissing noise. Engine-driven units use a pilot valve
instead of a pressure switch. It will discharge compressed air to atmosphere or open the intake valve upon reaching a
predetermined pressure setting.
PRESSURE VESSELS: ASME coded pressure vessels must not be modified, welded, repaired, reworked or subjected to operating
conditions outside the nameplate ratings. Such actions will negate code status.
DRIVE PULLEY
MAINTENANCE
Regular maintenance insures trouble-free operation. Your new compressor represents the finest engineering and construction
available. However, even the finest machinery requires periodic maintenance. A good maintenance program will add years of
service to your air compressor. The following is recommended as a minimum maintenance program. For your protection,
disconnect power supply after each day’s operation and drain air from system before performing any maintenance.
OIL TABLE
Temperature 0-40° 40° & Above
NON-DETERGENT – Straight Weight 10WT* 30WT*
*For maximum performance and service life, we recommend using ROLAIR Premium Quality compressor oil.
*Check and re-torque (see chart on pg. 7) only after
Recommendation Daily Weekly Monthly Quarterly
Check Oil Level X
Drain Moisture from Tank(s) X
Inspect Air Filter(s) X
Check for Unusual Noise or Vibration X
Inspect Belt Guard X
Check for Air or Oil Leaks X
Clean Exterior of Air Compressor X
Check Condition of Vibration Pads X
Tighten/Re-torque Bolts* X
Check Belt Tension X
Check Operation of Safety Valve X
Change Compressor Oil** X
Clean/Change Air Filter X
Perform Pump Up Time Test X
Check Operation of System Controls X
Check Air Tanks for Dents/Leaks X
pump has completely cooled to room temperature.
**Always make sure crankcase vent (breather) is free
and unobstructed when changing or checking oil.
MAINTENANCE HINTS:
1) Use a soap/water solution to check for air leaks.
2) Never clean filters with a flammable solvent.
3) Re-torque head bolts only after pump has cooled.
4) Move motor 1/4" and roll belts back on to increase belt
tension on electric units.
5) Never weld on air tank(s).
6) Use heat to loosen Loctite seal on drain valves, engine
pulleys and flywheels before attempting to remove.
TORQUE CHART (INCH/LBS)
k
y
y
Determine pump type using suffix of model number (Example: V5180K30 uses a K30 pump.)
Pump Type K17/K18 K24/K25 K28 K30 K35 K50 K60 K100
Head Bolts 243 243 347 347 347 694 347 694
Cylinder Bolts 182 182 330 330 330 521 330 521
Bearing Carrier Bolts 130 130 130 130 130 165 165 165
Connecting Rod Bolts 121.5 121.5 121.5 173.6 173.6 217 217 199.7
Flywheel 382 382 477 477 477 607 607 694
TROUBLESHOOTING
WARNING - Make sure you completely understand all of the safety warnings and operation of each system control
component before attempting any maintenance or repair. Always drain the tank pressure completely, make sure the
power cord is unplugged, and unit has time to cool before performing any maintenance or service operations.
PROBLEM CAUSE SOLUTION
Air leaks Correct air leaks
Restricted air intake Clean or replace intake element
Low discharge pressure
Knocking
Overheating
Excessive starting/stopping
Excessive belt wear
Oil in discharge air or
oil blowing out of
crankcase vent
Water in crankcase
(Oil appears milky in color)
Motor/compressor fails
to attain speed
NOTE: Reciprocating compressors consume a certain amount of oil under normal operation. If you are concerned
about your oil consumption, monitor and record oil consumption daily before consulting your dealer. When oil
consumption is normal and what appears to be milky oil is found in your lines, this is caused by small particles of oil,
along with water vapor, condensing in your air lines. To eliminate this problem: Air-Cooled Aftercoolers, Refrigerated
Dryers and Filters are available through your dealer.
Loose/slipping belt(s) Adjust belt tension
Compressor too small Perform pump-up time test
Blown gasket Replace head gaskets
Broken valves/worn rings Replace valve/rings
Loose pulley/flywheel Tighten appropriate item
Loose belt(s) Adjust belt tension
Lack of oil in crankcase Add oil
Internal pump problem Take pump in for service
Poor ventilation Relocate air compressor
Dirty cooling surfaces Clean compressor
Incorrect flywheel rotation Contact an electrician
Blown gasket(s) Replace head gaskets
Broken valves Replace valve/head gaskets
Excessive air leaks Correct air leaks
Unit too small for application Add/replace air compressor
Air storage capacity too small Add reserve air tan
Motor pulley or flywheel out of alignment Reposition pulley or flywheel
Flywheel/pulley wobble Replace appropriate item
Improper belt tension Adjust belt tension
Wrong oil viscosit
Improper flywheel rotation Contact an electrician
Crankcase overfilled Drain to proper oil level
Obstructed crankcase breather Clean or replace breather
Inadequate ventilation Relocate compressor
Restricted air intake Clean or replace intake element
Worn piston rings Take pump in for service
Infrequent cycling Install crankcase heater
Incorrect or inferior oil Use correct type of oil
Loose belts Correct belt tension
Low voltage Contact an electrician
Improper wiring Contact an electrician or factor
Defective check valve Replace check valve
Motor overload Push motor reset
Inoperable relief valve Replace pressure switch
Use correct type of oil
Guarantee
Associate Engineering Corporation warrants that all ROLAIR compressors will be free of defects in
material and workmanship for a period of twelve months from the date of initial retail purchase, or
eighteen months from the date of manufacture, whichever may occur first.
Should any failure to conform to this warranty be reported to the company within said period, the
company shall, upon purchaser shipping the compressor to our plant transportation prepaid, correct
such nonconformity by suitable repair or, at its option, furnish a replacement part F.O.B. our plant.
Associate Engineering Corporation shall not be liable for any unauthorized repairs, replacements,
adjustments to the compressors, or the costs of labor performed by the purchaser.
This warranty is expressly in lieu of all other warranties expressed, implied or statutory (including,
but not limited to, warranties of merchantability and fitness for purpose) and of any other
obligations, and/or liabilities on the part of Associate Engineering Corporation. Associate
Engineering Corporation neither assumes nor authorizes any other person to assume for it any
other obligations or liability in connection with or with respect to any compressor.
Associate Engineering Corporation shall in no event be liable neither for any consequential, incidental
or special damages nor for the improper selection of any compressor for a particular application.
Quality
Associate Engineering Corporation is devoted to continual quality control and thorough
research of the products we build. It is our creed to give you, the user, all of the
experience and engineering available in the production of every piece of equipment we
produce.
Our line covers the complete needs of today’s varied air requirements. Rely on ROLAIR for
all the newest and finest features that are available for the modern compressor.
606 South Lake Street > P.O. Box 346 > Hustisford, WI 53034-0346 > 920.349.3281 > fax 920.349.3691 > www.rolair.com
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