Stellar SRS-40 Manual

Owner’s Manual

Safety, Installation, Maintenance, and Operation

Model SRS-40

®

American Eagle, Inc.

190 State Street

PO Box 169

Garner, IA 50438 800-392-3015 Fax: [phone]

www.americaneagleacc.com

Subject to Change without Notification.		Manual Part No. 37245
© 2006 American Eagle		Last Revision: 8/30/06

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]

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Table of Contents

	Safety	Page 3
	Specifications	Page 4
	Operation	Page 5
	Maintenance	Page 6
	Installation	Page 11
	Assembly Drawings	Page 17
	Replacement Parts	Page 19
	Troubleshooting	Page 20
	Warranty	Page 22

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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.

The SRS-40 Rotary Screw 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 before performing maintenance or repairs.

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

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 power source is connected. Accidental engagement of the tool can cause serious injury.

Before performing any maintenance on the 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 before energizing the power source. Be sure all hose connections are tight.

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 properly assembled.

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.

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 8000 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.

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Specifications

Compressor System Description

• 19-20 GPM Hydraulic System	• 2000 PSI System Pressure
• 2500 PSI Pressure Relief Setting	• 12 VDC Solenoid Control Valve
• All Steel Plumbing W/ JIC Fittings	• 6061 Aluminum Manifold
• 861 CFM, 12 Volt Cooler Fan	• Air Pressure Control Valve
• Belt Drive	• Max. Air Pressure 150 PSI
• Compressor RPM (small sprocket)	• 40 CFM @ 100 PSI With
7500-8000 RPM	Compressor Running @ 7500
	RPM @ 20 GPM

General Information
• Weight:	225 lbs.
• Delivery:	40 CFM @ 100 PSI
• Maximum Working Pressure:	150 PSI
• Relief:	2500 PSI
• Maximum Compressor Speed:	7500 RPM
• Dimensions:	26.81”L x 17.44”W x 19.63”H
• Electrical:	12 VDC
• Crankcase Oil Capacity:	4 Quarts
• Oil Reservoir Capacity:	Minimum: 26 Gallon Reservoir

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Operation

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

Inspect unit for any visible signs of damage.

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. Note: 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 hoses (air and hydraulic) for weak or worn condition and make sure that all connections are secure.

Check the air intake filters on each head to make certain that they are clean and unobstructed. Dirty air filters are a possible cause of reduced air output.

General Information

To use the compressor, start the vehicle engine and engage the hydraulic system. The compressor can now be activated using the compressor switch. This energizes the hydraulic solenoid sending oil to the hydraulic drive motor and starts the compressor. Through the air pressure switch and pilot valve, the system will now function automatically. Once engaged, adjust the engine speed control to ensure that the compressor speed does not exceed 8000 Rpm under load. Adjustment instructions are provided with the speed control unit.

Air Pilot Valve Operation

(Head Unloading System)

When the hydraulic system is engaged the compressor will pump air into the receiver until the pressure reaches 150 psi. At this time the air pilot valve senses the pressure in the receiver and engages an intake valve hold-open mechanism. The compressor will run free until the pressure in the receiver falls below 115 psi and the air pressure valve disengages the intake valve hold-open mechanism to allow the

compressor to pump air. See head unloading system for detailed views and adjustment instructions on the next page.

Operating Notes:

This rotary screw compressor must not be used for breathing air. To do so will cause serious injury whether air is supplied direct from the compressor source or to breathing tanks for later use. Any and all liabilities for damage or loss due to injuries, death and/or property damage, including consequential damages stemming from the use of this compressor to supply breathing air will be disclaimed by the manufacturer.

The use of this compressor as a booster pump and/or to compress a medium other than atmospheric air is strictly non-approved and can result in equipment damage and/or injury. Nonapproved uses will also void the warranty.

Never use plastic pipe or improperly rated metal pipe. Improper piping materials can burst and cause injury or property damage.

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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. Before performing any maintenance function “Lock Out” or “Tag Out” all sources of power. Be sure all air pressure in unit is relieved. Failure to do so may result in injury or equipment damage.

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

Replace Coalescering/Separator Cartridge

12

Inspect and clean compressor valves

6

-

6

Replace hydraulic filter

Replace air filters

3

Tighten all fittings and fasteners

3

Check all electrical connections

3

Inspect and clean air check valve

250

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 3 QUARTS.

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.

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SRS-40 Oil Level

The oil level in the oil receiver container is an important factor for the operational reliability of the system.

Check Intervals:

1.Before starting unit.

2.Every 100 operating hours

Check Procedures:

1.Switch off the unit with main power and prevent it from accidentally being turned on.

2.Allow one full minute to pass after stopping compressor.

3.Unscrew the cap of the inlet connection pipe with the oil receiver discharged.

4.Check the oil level with the dipstick.

5.Add oil to level off if necessary.

6.Tighten cap back into place and unit is ready to be put into service

7.Check for impermeability and replace the o-ring if required.

Note:

•The screw-type cap of the compressor crankcase is equipped with a pressure release hole, which emits air/oil if the pressure has not been alleviated from the separator receiver. In this case wait a few minutes for the pressure to release before removing cap totally.

•The oil fill is designed in such a way that the unit cannot be over filled. Any excess oil runs out the fill.

Condensation Drain

The condensation in the oil affects the operation safety and the life of the screw compressor unit. If you operate the screw compressor unit for a short period of time and therefore at a low operation temperature, i.e. below the switch temperature of the thermal oil bypass valve, you run the risk of

condensation collecting in the oil separator receiver. The relative humidity in the intake air determines the quantity of condensation.

Possible Malfunctions:

•Insufficient compressor lubrication.

•Insufficient air/oil separation and high differential pressure in the purifier cartridge.

•Corrosion and rust formation due to condensation in the oil.

Drain the condensation regularly when the compressor unit is cold prior to startup.

Maintenance Procedure:

1.Switch off the main power to the unit.

2.Slowly unscrew the oil fill cap.

3.Unscrew the oil drain plug carefully and place a container underneath.

4.Drain the condensation from the separator receiver until oil starts to come out. Then replace the drain plug.

5.Fill separator receiver with oil up to maximum, then close oil fill.

6.Switch on compressor and run for 3 minutes.

7.Check oil level and fill if necessary.

8.Dispose of condensation in accordance with local and federal regulations.

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