Stellar Class 3 V360 User Manual

®

OWNER’S MANUAL

Safety, Installation, Maintenance, and Operation

Model V360 Compressor
Model SUH 43 Compressor
Model SHD 43 Compressor

Subject to Change without Notification.
© 2007 Stellar Industries, Inc.

Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: [phone]

www.stellarindustries.com

Manual Part No. 40983
Last Revision: 3/05/07

Class 3 Compressor Manual Revisions

Date of Revision Description of RevisionSection Revised

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

General Specifications . . . . . . . . . . . . . . . . . . . . . .2

Compressor System Description . . . . . . . . . . . . . . .2

SHD-43 Drive System Description . . . . . . . . . . . . . .2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

General Operation Notes . . . . . . . . . . . . . . . . . . . .3

SHD-43 Operation Notes . . . . . . . . . . . . . . . . . . . . .3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Compressor Installation . . . . . . . . . . . . . . . . . . . . . .5

SHD-43 Installation . . . . . . . . . . . . . . . . . . . . . . . . . .6

Pressure Setting Instructions . . . . . . . . . . . . . . . . . .7

i

Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Crankcase Group (Tapered Shaft) . . . . . . . . . . . .8

Crankcase Group (Straight Shaft) . . . . . . . . . . . . .9

Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Head Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Head Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Optional Head Unloader . . . . . . . . . . . . . . . . . . .13

Flywheel Options . . . . . . . . . . . . . . . . . . . . . . . . . .14

Clutch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

SUH-43 Compressor Assembly . . . . . . . . . . . . . . .16

SHD-43 Compressor Assembly . . . . . . . . . . . . . . .17

Hydraulics/Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . .18

SHD-43 Control Kit . . . . . . . . . . . . . . . . . . . . . . . . .18

Typical Hydraulic Circuit for Tandum (Two Part)

Pump with Multiple Components . . . . . . . . . .19

Typical Hydraulic Circuit for Single Stage

Pump with Multiple Components . . . . . . . . . .19

Typical Hydraulic Circuit for Compressor

with Auxiliary Cooler . . . . . . . . . . . . . . . . . . . .20

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

General Troubleshooting . . . . . . . . . . . . . . . . . . .22

SHD-43 Troubleshooting . . . . . . . . . . . . . . . . . . . . .23

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . .26

ii Class 3 Compressor Owner’s Manual

Introduction

American Eagle Compressors are designed
to provide safe and dependable service for
a variety of operations. With proper use and
maintenance, American Eagle Compressors
will operate at peak performance for many
years.

This manual contains information vital to the
safe use and efficient operation of this unit.
Following the information provided within this
manual can ensure the longevity of the
compressor. Carefully read and study the
operator’s manual before using the unit.
Failure to adhere to the instructions could
result in property damage or even serious
bodily injury to the operator or others close
to the compressor.

A copy of this manual is provided with every
compressor and shall remain with the
compressor at all times. Information
contained within this manual does not cover
all maintenance, operating, or repair
instructions pertinent to all possible situations.
This manual is not binding.

American Eagle reserves the right to
change, at any time, any or all of the items,

components, and parts deemed necessary
for product improvement or
commercial/production purposes. This right
is kept with no requirement or obligation for
immediate mandatory updating of this
manual.

This product manual is not intended as a
training manual for beginners or unskilled
operators. This manual offers guidelines for
correct and safe usage of the compressor,
maintenance, and troubleshooting. If more
information is required or technical
assistance is needed, please contact AE
Technical Support.

Some sections of this manual contain
information pertaining to all American Eagle
manufactured compressors and may or may
not apply to your specific model.

If this manual becomes damaged,
misplaced, or unreadable at any point, or if
you feel that any part of this manual is
unclear or incorrect, please contact AE
Technical Support at 800-321-3741 or email
at [e-mail]

For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at

800-321-3741

Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST

Or email at the following addresses:

Technical Questions, and Information [e-mail]

Order Parts [e-mail]

Warranty Information [e-mail]

Safety 1

Safety

This manual contains vital information for the safe use and efficient

operation of this unit. Carefully read the operators manual before starting

the unit. Failure to adhere to the instructions could result in serious bodily

injury or property damage.

Every American Eagle Compressor will
provide safe and dependable service if
operated according to instructions. Read
and understand the safety precautions
given in this manual and on the decals
attached to the shields. Failure to do so can
result in personal injury or equipment
damage.

Operators and maintenance personnel must
always comply with the safety precautions.
These precautions are given here for your
safety. Review them carefully before
operating the compressor and befor
performing maintenance or repairs.

Supervising personnel should develop
additional precautions relating to the
specific work area and local safety
regulations.

e

before energizing the hydraulic power
source. Be sure all hose connections are
tight, both air and hydraulic.

Establish a training program for all operators
to ensure safe operation.

Do not operate the compressor unless
thoroughly trained or under the supervision
of an instructor.

Do not operate the compressor if it is
damaged, improperly adjusted or not
completely or pr

Never operate the compressor with any of
the guards removed.

Do not attempt to adjust or disable the
compressors air pressure relief valve. This
valve limits the air pressure to 150 PSI.

operly assembled.

Precautions

Always wear safety equipment such as
goggles, ear plugs and head protection at
all times when operating the compressor.

Do not inspect or clean the compressor
while the hydraulic power source is
connected. Accidental engagement of the
tool can cause serious injury.

Before perfor
compressor, place a warning tag on the
hydraulic power source or disconnect the
hoses from the compressor motor to prevent
accidental startup of the compressor.

Always connect hoses to the compressor

ming any maintenance on the

The surface of the air compressor and the
plumbing between the compressor and the
cooler may reach temperatures above 150
degrees. Touching these surfaces during
operation can cause burns.

The air taken in by the air compressor must
be free of flammable fumes and vapors.

Compressor speed should not exceed 1300
RPM.

Use and operate this air compressor only in
full compliance with all pertinent O.S.H.A.
requirements and all Federal, State and
Local codes or requirements.

2 Class 3 Compressor Owner’s Manual

Specifications

Compressor System Description

• Cast Iron Crankcase Casting • Heavy Ductile Iron Crankshaft

• Cast Aluminum Cylinder Head • Micro-honed Connecting Rods

• High Temperature Precision Pistons • Tapered Roller Bearings

• Stainless Steel Reed Valves • Pressure Lubricated System

• Heavy Duty Journal Bushings • Oil Pressure Gauge

• Pulsation Manifold

SHD-43 Drive System Description

• 10 GPM Hydraulic System • 1800 PSI System Pressure

• 2500 PSI Pressure Relief Setting • 12 VDC Solenoid Control Valve

• All Steel Plumbing W/ JIC Fittings • 165 Sq. In., 300 BTU Cooler

• 361 CFM, 12 Volt Cooler Fan • 6061 Aluminum Manifold

• Direct Drive Coupling • Air Pressure Control Valve

General Specifications

• Model: V360C

• Weight: 87 lbs (SHD-43: 165 lbs)

• Delivery: 28 CFM @ 100 PSI

• Maximum Working Pressure: 155 PSI

• Dimensions: 23”L x 18”W x 18”H

• Oil Capacity:

• Cylinders: Four Cylinder(Single Stage)

• Pressure Switch Presets: Engage - 115 PSI

1 Quart

Disengage - 150 PSI

Operation 3

Operation

General Operation Notes

Each compressor is bench tested under load at the factory to ensure proper break-in and
operation. While it is not necessary to follow any break-in procedure, the following checks
should be made before putting the unit into service and periodically during use.

Before Start-Up

Check the oil level in the compressor with the dipstick on the unit. If oil is needed, use
American Eagle synthetic compressor oil (P/N C0087) or an equivalent synthetic oil.

There may be oil left in the crankcase from the factory bench test. Overfilling may cause
the compressor to back blow oil. Always check the oil level and fill to the designated
marking on the dipstick before putting the unit into service.

Check the air intake filters on each head to make certain that they are clean and
unobstructed. Dirty air filters ar

e a possible cause of reduced air output.

Note:

To use the compressor, start the engine and engage the hydraulic system with the
compr
function automatically. Once engaged, adjust the engine speed control to ensure that the
compressor speed does not exceed 1300 RPM under load.

essor toggle switch. Through the hydraulic valve manifold, the system will now

SHD-43 Operation Notes

If adjustment is necessary for cable operated speed controls, loosen the jam nut on the
cable end, make the adjustment and retighten the jam nut.

For electronic operated speed controls, adjust speed adjustment screw as needed to set
RPM.

For setting engine RPM through the chassis ECM, contact local chassis dealer.

When the air pressure falls below 120 PSI, the 12 volt electric solenoid opens allowing
hydraulic oil to flow to the hydraulic drive motor then back to the manifold and through
the oil cooler assembly. Once the air pressure reaches 150 PSI the solenoid closes
shutting off the oil flow to the motor and diverts the oil to the oil cooler.

With the compressor engaged, the main cooling system, which consists of an oil cooler,
electric fan motor and fan continually runs drawing ambient air through the cooler fins
and across the fan assembly dischar
cover assembly.

ging heated air past the compressor and out the

4 Class 3 Compressor Owner’s Manual

Maintenance

The following table is a list of routine maintenance items, including service intervals. Service
intervals are listed as hours, days, or weeks, whichever occurs first. American Eagle
recommends that these service intervals be followed.

Service Intervals

Maintenance operation Daily Weekly Monthly Hourly

Drain air tanks

Check crankcase oil level

Check fittings and airlines

Check hydraulic fluid level

Inspect and clean air intake filters

Clean and operate safety valves

Clean cooling fins on radiator

Inspect check valve

Inspect and clean compressor valves 6

Replace hydraulic filter 6

Replace air filters 3

Tighten all fittings and fasteners 3

Check all electrical connections 3

Check compr

Inspect and clean air check valve 250

essor reed valves

250

CHANGE CRANKCASE OIL (see footnote below)

Under normal operating conditions, oil changes are required every 3 months. When operating in a
dirty environment, change the oil more frequently as your particular operating condition dictates.

USE AE SYNTHETIC COMPRESSOR OIL P/N C0087.

COMPRESSOR CRANKCASE CAPACITY IS 1 QUART.

General preventative maintenance includes maintaining proper fluid level in both systems and the
general cleanliness of the equipment. Proper fluids according to the specifications are required.

Installation 5

Installation

Compressor Installation

Component Installation

This section pertains to the installation of the air compressor, PTO, pump and

other related items. The instructions are intended as a guide to assist you with

particular installation. These instructions will provide only general information.

Torque and Procedure Chart

Pulsation Chamber Assembly

Torque Value: 31 FT. LBS.

Procedure: See Head Installation Procedure Section

Head Assembly

Torque Value: 31 FT. LBS.

Procedure: Assemble head on the cylinder with head bolts started only, not tight. Snug
(6) head bolts to light torque. Tighten (6) head bolts to 31 Ft-lbs. torque, doing the (2)
long center bolts first and the (4) short bolts last. After five hours of use re-torque bolts to
31 Ft-lbs.

Cylinder Assembly

Torque Value: 20 FT. LBS.

Procedure: After assembling cylinder over pistons and setting into place, tighten (6) cap
screws finger tight. In a criss-cross pattern, tighten bolts evenly so all bolts are hand snug.
Again in a criss-cross pattern torque each bolt to 20 Ft-lbs., checking each bolt twice.
After five hours of use, re-torque bolts to 20 Ft-lbs.

Connecting Rod Assembly

Torque Value: 18 FT. LBS.

Procedure: Assemble rod onto the crankshaft taking care to align the machined
surfaces together and tighten cap screws finger tight. Tighten bolts until hand tight and
torque to 18 Ft-lbs. Check twice the torque reading before final assembly of the
cylinders.

6 Class 3 Compressor Owner’s Manual

Return Line

Pressure
Line

FAN

GND

CPRSR

SPD CTRL

PRESSURE

SWITCH

LINE

MOTOR

HYDRAULIC

MANIFOLD

COMPRESSOR (12V INPUT)
GROUND
SPEED CONTROL

C
B
A

C
B
A

SHD-43 Installation

Pump Assembly:

The pump assembly may either be installed directly
on the PTO or as an optional method, may be
driven by a driveline from the PTO. Pump
manufacturers provide specific installation
information for their products and should be
consulted if questions arise.

PTO Assembly:

Check with the PTO manufactures representative
for specific instructions regarding your particular
make, model, and year of vehicle. As some trucks
may require modification of the transmission cross
member and the exhaust system, the
manufacturer’s instructions should be followed to
insure proper installation of the PTO.

Compressor Assembly:

Prepare the mounting location of the compressor
by locating and drilling four (4) holes, 7/16”
diameter as per the mounting pattern of the air
compressor base. Using four (4) 3/8” x 1.25 GR-5
cap screws, 3/8” flat washers, and 3/8” nyloc nuts,
secure the compressor in place. The compressor is
air cooled, and must have a clean supply of
cooling air to the fan with minimum restrictions.
Adequate space must be provided for proper
circulation of air.

Electrical Connections:

From the air pressure switch there are two (2) wires,
red and black, running to the outside of the
compr

essor housing. Connect the black wire to the
vehicle frame or other suitable ground. Mount a
single throw toggle switch in a convenient location

e from the compressor to

and connect the r

ed wir
this switch. Connect the other switch terminal to a
fuse holder and then to a 12-volt power supply. A

om the air compressor switch

ed fr

equir

e is r

d wir

thir
when connecting the speed control into the
system. (See drawing below)

Electric speed control:

An optional electric or electronic speed control
must be used to maintain proper operating speed
of the air compressor. The engine speed control will
automatically increase from idle to preset speed
when engaged and decrease when disengaged.
The electric cable pull speed control American
Eagle P/N C0873 is used on most gasoline engines.
The electronic speed controls are used only on Ford

7.3 and 6.0L diesel engines. Proper installation
instructions are provided with each system.

Hydraulic System:

The hydraulic system consists of the pump, oil
reservoir, filters and hoses. Installed on the
compressor is a valve block assembly that controls
the flow to the hydraulic motor. To this block, a 1/2”
high-pressure hose must be attached. This hose
comes from the hydraulic pumps pressure side. A
3/4” minimum low-pressure return line is connected
to the oil cooler outlet and is routed to the oil
reservoir. American Eagle recommends a sufficient
sized reservoir be provided which includes the
proper suction and return filters. The cooler on the
compressor is designed and sized to cool the air
compressor efficiently. An auxillary oil cooler is
required when additional hydraulically operated
equipment are added to the hydraulic system.
Pressure on the return line exceeding 200 PSI can
and will cause damage to the filter, cooler, and
components of the compressor hydraulic system.