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General Operation and Parts Instructions for Gasoline Compressor Outfits MODEL NO . DACE - 7161 - 2 ENGINE HORSE POWER 11liP COMPRESSOR BORE 1.96 / 4.3 COMPRESSOR STROKE 2.17 AIR TANK CAPACITY 30 GAL . APPROXIMATE UNLOADER PRESSURE 175 PSIG SCFM @ 100 psig 12.5 SCFM @ 175 Psig 12,0 e This product is not equipped with a spark arresting muffler . If the product will be used around flammable materials , oronland covered with materials such asagricultural crops , forest , brush , grass , or other similar items , then an approved spark arrester must be installed and is legally required in the state of California . It is a violation of California statutes section 130050 and / or sections 4442 and 4443 of the California Public Resources Code , unless the engine is equipped with a spark arrestor , as defined in section 4442 , and maintained in effective working order . Spark arresters are also required on some U . S . Forest service land and may also be legally required under other statutesand ordinances . e Engineexhaust from this product containschemicalsknown , incertain quantities , to causecancer , birth defects or other reproductive harm . J _ , V / / . B / SS A / R _ € _ O / ImulqJIIY _ 13 Indus _ lal Dr . • Jacb _ n , TN 38301 MGP - DAC - 7161 - 2A 7 / 9 / 99
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TABLE OF CONTENTS Page No . SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 COMPRESSOR DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10 Pre - lnstallationInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Vibration Mounting Kit ( StationaryCompressorOutfits ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Location of the Compressor Outfit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 9 Air Line Piping ( StationaryCompressor Outfits ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 14 OperatorControls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12 Daily Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 14 Break - In Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 17 Routine Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cleaning the Air Compressor Outfit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Checking and Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Checking and Changing Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DrainingWater fromAir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Checking and Adjusting BeltTension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 19 Replacing Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 18 Engine Pulleyand FlywheelAlignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Check Valve Inspectionand Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 - 19 Servicing Intake and ExhaustValves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 24 Air Compressor Diagram & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - 27 Compressor Pump Diagram & Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 - 29 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ORDERING REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 PAGE 2
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SAFETY GUIDELINES - DEFINITIONS This manual contains information that is important for you to know and understand . This information relates to protect ing YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS . To help you recognize this information , we use th _ symbols to the right . Please read the manual and pay attention to these sections . IA CAUTION I I Jk DANGER I CAUTION indicates a potentially hazardous situation DANGER indicates an imminently hazardous situation which , if not avoided , may result in minor or moder - which , if not avoided , will result in death or serious injury . I CAUTION I I _ WARNING I CAUTION used without the safety alert symbol indi - WARNING indicates a potentially hazardous situation cates a potentially hazardous situation which , if net which , if not avoided , could result in death or serious avoided , may result in _ roDertv damaae . injury . IMPORTANT SAFETY INSTRUCTIONS • SAVE THESE INSTRUCTIONS , IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE . READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT , WHAT CAN HAPPEN HOW TO PREVENT IT HAZARD GASOUNE AND GASOLINE VAPORS CAN RISK OF TURN ENGINE OFF AND ALLOW IT TO BY COMING INTO CON - COOL BEFORE ADDING FUEL TO THE EXPLOSION OR FIRE TACT WITH HOT COMPONENTS SUCH AS TANK . EQUIP AREA OF OPERATION WITH THE MUFFLER , A FIRE EXTINGUISHER CERTIFIED TO GASES , OR FROM AN ELECTRICAL SPARK . HANDLE GASOLINE OR FUEL FIRES . COMBUSTIBLE MATERIALS WHICH COME ADD FUEL OUTDOORS OR IN A WELL INTO CONTACT WITH HOT ENGINE PARTS VENTILATED AREA . MAKE SURE THERE CAN BECOME IGNITED . ARE NO SOURCES OF IGNITION , SUCH AS CIGARETTES NEAR REFUELING LOCA - TION . OPERATE COMPRESSOR IN AN OPEN AREA AWAY FROM DRY BRUSH , WEEDS OR OTHER COMBUSTIBLE MATERIALS . STORE FUEL IN A SECURE LOCATION AWAY FROM COMPRESSOR . UNATTENDED OPERATION OF THIS PROD - ALWAYS REMAIN IN A'FrENDANCE WITH UCT COULD RESULT IN PERSONAL INJURY THE PRODUCT WHEN IT IS OPERATING . RISK OF BURSTING AIR TANK THE FOLLOWING CONDITIONS COULD LEAD TO A WEAKENING OF THE TANK , : AND RESULT IN A VIOLENT TANK EXPLOSION 1 . FAILURE TO PROPERLY DRAIN DRAIN TANK DAILY OR AFTER EACH CONDENSED USE . IF TANK DEVELOPS A LEAK , CAUSING RUST AND THINNING OF THE REPLACE IT IMMEDIATELY WITH A NEW STEEL TANK . TANK OR NEW COMPRESSOR OUTFIT . 2 . MODIFICATIONS OR A'I - FEMPTED NEVER DRILL INTO , WELD , OR MAKE _ Y REPAIRS MODIFICATIONS TO THE TANK OR ITS ATTACHMENTS . PAGE 3
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HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT RISK OF BURSTING AIR TANK ( cont'd ) 3 . UNAUTHORIZED MODIFICATIONS TO THE TANK IS DESIGNED TO WITHSTAND THE UNLOADER VALVE . SAFETy SPECIFIC OPERATING PRESSURES . VALVE . OR ANy NEVER MAKE ADJUSTMENTS OR PART ( ; WHICH CONTROL TANK SUBSTITUTIONS TO ALTER THE FAC - TORY SET OPERATING 4 . EXCESSIVE VIBRATION CAN WEAKEN DO NOT REMOVE THE STIFFENER BAR AND CAUSE RUPTURE OR CONNECTING THE COMPRESSOR PUMP EXPLOSION . TO THE ENGINE , EXCEPT TO ADJUST WILL OCCUR IF THE COMPRESSOR 18 BELT TENSION , THEN SECURELY OR IF THE TIGHTEN THE STIFFNER BAR NUTS . ENGINE OPERATES ABOVE RECOM - THIS BAR CONTROLS OUTFIT VIBRA - MENDED RPM . T1ON . ATTACHMENTS & ACCESSORIES EXCEEDING THE PRESSURE RATING OF FOR ESSENTIAL CONTROL OF AIR PRES - _ R TOOLS . SPRAY GUNS , AIR OPERATED SURE , YOU MUST ACCESSORIES , TIRES AND OTHER REGULATOR AND PRESSURE GAUGE INFLATABLES T X - OF YOUR COMPRES - PLODE OR FLY APART , AND COULD RESULT SOR . FOLLOW THE EQUIPMENT MANU - IN SERIOUS INJURY . FACTURERS RECOMMENDATION AND NEVER EXCEED THE MAXIMUM ALLOW - ABLE PRESSURE RATING OF A1TACH - MENTS . NEVER USE COMPRESSOR TO INFLATE SMALL LOW - PRESSURE Oml - JECTS SUCH AS CHILDREN'S TOYS . FOOTBALLS . BASKETBALLS . ETC . RISK FROM THE _ STREAM CAN ALWAYS WEAR ANSI Z87 . 1 APPROVED CAUSE SOFT TISSUE DAMAGE TO EX - SAFETY GLASSES WITH SIDE SHIELDS FLYING OBJECTS POSED SKIN AND CAN PROPEL DIRT , WHEN USING THE COMPRESSOR . CHIPS , _ AND SMALL OBJECTS AT _ RESULTING IN NEVER POINT ANY NOZZLE OR PROPERTY DAMAGE OR PERSONAL INJURY . SPRAYER TOWARD ANY PART OF THE BODY OR AT OTHER PEOPLE OR ANIMALS . I ALWAYS TURN THE COMPRESSOR OFF FROM THE AIR HOSE AND TANK BEFORE ATTEMPTING MAINTENANCE , AI " rACHING TOOLS OR ACCESSORIES . BREATHING EXHAUST FUMES FROM ALWAYS OPERATE AIR COMPRESSOR RISK TO BREATHING ENGINE _ SERIOUS INJURY OR IN A CLEAN . WELL VENTILATED AREA . DEATH . AVOID ENCLOSED AREAS SUCH AS GARAGES , BASEMENTS , STORAGE SHEDS , ETC . , WHICH LACK A STEADY EXCHANGE OF AIR . UNIT IN ENCLOSED LOCATIONS OCCUPIED BY HUMANS OR ANIMALS . KEEP CHILDREN , PETS AND OTHERS AWAY FROM AREA OF OPERATION . THE COMPRESSED AIR FROM YOUR NEVER INHALE AIR FROM THE COM - COMPRESSOR PRESSOR EITHER DIRECTLY OR FROM A THE AIR STREAM MAY CONTAIN BREATHING DEVICE CONNECTED TO THE CARBON MONOXIDE , TOXIC VAPORS OR COMPRESSOR . SOLID PARTICLES FROM THE TANK . SUCH AS PAINT , WORK IN AN AREA WITH GOOD CROSS - PAINT SOLVENTS , PAINT REMOVER , INSEC - READ AND TICIDES , WEED KILLERS , ETC . . CONTAIN PROVIDE ON HARMFUL VAPORS AND POISONS . THE LABEL OR SAFETY DATA SHEETS FOR THE MATERIAL YOU ARE SPRAY - ING . USE A NIOSH / MSHA APPROVED DESIGNED FOR USE WITH YOUR SPECIFIC APPLICATION . PAGE 4
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HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT THE ENGINE CAN START ACCIDENTALLY ALWAYS SP RISK FROM PLUG AND BLEED PRESSURE FROM IF THE FLYWHEEL IS TURNED BY HAND OR MOVING PARTS THE TANK BEFORE PERFORMING MOVED BY PULLING ON THE STARTER MAINTENANCE . ROPE . MOVING PARTS SUCH AS THE PULLEY , NEVER OPERATE THE _ FLYWHEEL AND BELT CAN CAUSE W _ H GUARDS OR COVERS WHICH ARE IF THEY COME INTO DAMAGED OR REMOVED . CONTACT WITH YOU OR YOUR CLOTHING . _ L _ COMPRES - SOR WITH DAMAGED OR MISSING PANTS ANY REPAIRS REQUIRED ON THIS PROD - UCT SHOULD BE PERFORMED BY OR AI " rEMPTINO TO REPAIR COMPRES - AUTHORIZED SERVICE CENTER PER - SOR WITH PROTECllVE SHROUDS SONNEL . REMOVED CAN EXPOSE YOU TO MOVING PAR _ AND DAN RESULT IN SERIOUS i INJURY . RISK OF BURNS TOUCHING EXPOSED METAL SUCH AS THE NEVER TOUCH ANY EXPOSED METAL COMPRESSOR HEAD OR OUTLET TUBES OR PANTS ON ENGINE OR COMPRESSOR CONTACT WITH HOT ENGINE PARTS SUCH DURING OR IMMEDIATELY AFTER OPERA - AS THE MUFFLER _ J _ L _ I _ , T _ U _ J _ TION . ENGINE AND COMPRESSOR WILL BURNS . REMAIN HOT FOR SEVERAL MINUTES AFTER OPERATION . THE GASOLINE ENGINE , THE ENGINE DO NOT REACH AROUND PROTECTIVE MUFFLER , THE COMPRESSOR HEAD AND SHROUDS OR A'I - rEMPT MAINTENANCE TUBING BECOME VERY HOT DURING UNTIL UNIT HAS BEEN ALLOWED TO COOL . OPERATION . PAGE 5
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GENERAL INFORMATION You have pumhaeed a complete compressoroutfit con - applications . Refer to Figure 1 for a photographof sistingof an air compressor , ASME approved airtank , the compressorand to identifythe majorcomponents gasoline engine , and associated controls and instru - of the compressor . ments . The compressor outfit you have selected is a two stage stationaryoutfit . A regularlyscheduled program of preventive mainte - nanceis necessaryto insurethe longlifethat has been Your new compressor can be used for operatingpaint designed into your DeVilbiss compressor outfit . This sprayers , air tools , grease guns , airbrushes , caulking instruction manual , along with regular maintenance guns , and sand blasters , spraying weed killer and will maintainyour compressor outfit ingood working insecticides , etc . An air pressure regulatormay be order . Beforeoperatingor performingany maintenance necessary for some of these onyour outfit , referto these publications . DESCRIPTION OF OPERATION The gasoline engine uses a pulley and drive belt to tank pressure the unloader valve exhausts air to at - drive the compressor flywheel . The flywheel turns the mosphere ( blowoff ) ; tank pressure closes the check compressor crankshaft causing the up and down move - valve retainingairpressureinsidethe tank . When tank ment of the pistons in the cylinder ; this up and down pressure drops to a pre - determined pressu , = , ; 3 , = movement draws and compresses the air . unloader valve closes , and air pressure opens the check valve allowingcompressed air into the tank . As On the down strokeofthe piston , airisdrawn inthrough maximum tank pressure is reached , if the unloader the air intake . The exhaust valves remain closed . On valve malfunctions and compressed air is not ex - the upstroke of the piston , both the valves are closed haustedat ornear its blowoff setting , the airtank safety and air is compressed in the cylinder . As pressure valve wilt protect the airtank against high pressure by builds inthe cylinderthe exhaust valveopens and the popping at its factory set pressure . The safety valve compressed air is forced out of the cylinder through popping pressure is slightly higher than the unloader the check valve and into the air tank . This process valve blowoff pressure . continuesuntilthe air pressurereachesmaximum tank pressure . This compressor outfit is equipped with a gas saving throttlecontroldevice . When maximumtank pressure Working airpressure becomes availablewhenthe com - is reached and the unloader valve opens the throttle pressor has raised the tank pressure above that re - control is also activated , The throttlecontrol holdsthe quired at the air discharge valve . The air intake must engine at a factory set idlingspeed untilair pressure be kept clear of allobstructions which could interfere in the tank drops to reset or minimum tank pressure . with air delivery to the compressor . At reset pressure when the unloader valve closesthe throttle control is reactivated and the engine acceler - ates to full throttle . All gasoline compressor outfits are continuouslyrun - ning outfits controlled bytank pressure . At maximum PAGE 6
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Pump Air Intake Engine Oil Filter Dipstick Beltrd Gas Gua Engine Fuel Two - Stage Tank Pump Engine Air Filter Pump Oil Engine Oil Fill Plug Drain ( Not Shown ) Throttle Control Pump Oil Sight Glass Oil Drain Plug Pressure - Air Outlet For Gauge Discharge Valve Drain Valve ( Not Shown ) Figure I - Typical Gasoline Compressor Outfit PAGE 7
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INSTALLATION 2 . PRE - INSTALLATION INSPECTION Insertthevibrationmountsinthe mountingholes . Place a fiat washer underthe mountingsurface and secure each mount witha Iockwasher and NOTE nut . See Figure 3 . Each air compressor outfit is care - fully checked before shipment . With improper handling , damage may result in transit and cause problems in compressor operation ; a bent crankshaft , etc . Immediatelyon equipmentarrival , checkfor both con - cealed andvisibledamages to avoid expensesbeing incurred to correctsuchproblems . This shouldbe done regardlessof any visible signsof damage to the ship - pingcontainer . Reportany damages to carrierandar - range for inspectionof goodsimmediately . LOCKWASHER NUT VIBRATION MOUNTING KIT ( Stationary Compressor Outfits ) Figura3 - 1nstallation of Vibration Mounting Kit 3 . Set the outfitontop of the vibrationmounts Bolting legs to a stiff surface can ( the exposed threaded ends ) and secure cause tank rupture resulting in lseriousy each mount to the air tank legs with lock injury or damage . Do not permanent washer and nut . mount compressor to any surface with - out using the vibration mount kit . LOCATION OF THE COMPRESSOR OUTFIT Portable compressor outfits may be permanently mounted in one location such as a truck bed , if de - sired . A vibration mount kit is included with the outfit for this purpose . 1 . In order to maintain adequate ventilation for Engine exhaust contains toxic carbon compressor cooling and to avoid contactwith monoxide . Operate the engine in a welln ventilated area only . If inhaled , it ca pick - up truck bed , always mount the outfit at cause dizziness , unconsciousness and least 8 inches from any vertical wall . Using the possibly death . holes in the airtank support legs as a guide , mark and drill four 5 / 16 inch diameter holes in The air compressoroutfitshould be located as close the mounting surface . as possibleto the pointwhere the compressedair is to be used . The area selected should be dry , clean , cool , and well ventilated . Make certain that the outfit is mounted levelon a solidfoundation so nostrain is To prevent excessive vibration which imposedon the supportfeet or base . Keep the outfit may cause tank rupture or explosion , away from areas which have dirt , vapor , and volatile never remove the engine stiffener bar fumes inthe atmosphere which may clogand gum or increase the engine RPM . Makear the intakefilterand valves causinginefficient sure the engine bolts and stiffener b nuts are tight . Do not operate the outfit operation . Where this not practicala remote air if the rubber feet are not attached . intakeis recommended . PAGE 8
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NOTE Pipe thread sealant must be used onall threads , and Where a remote air intake is used , enlarge alljoints are to be made up tight , since smallleaks in the side of the air intake piping by one pipe the pipingsystemare the largestsinglecause of high size for each t0 feet of length . operatingcosts . All piping should be slopedto an accessible drain Stationary outfits must be bolted or lagged to the floor pointand alloutlets should be taken from the top of to prevent movement . When lagging down , leave a mini - the main distributionair line so that moisturecannot mum of 1 / 8 inch between the bolt and support feet . enter the outlet . The use of vibration pads at each support foot is re - quired to eliminate the possibility of tank rupture . The main distribution air line should notbe smaller than the compressorair dischargevalve outlet . A The flywheel sideof the outfitshouldbe placed toward smaller line will restrictthe flow of air . For longair the wall and protected with a totally enclosed belt lines , refer to Table 2 , Pipe Sizes for Compressed guard . In no case should the flywheel be closer than Air Lines , for recommended pipe sizes . It is recom - 12 to 18 inches from the wall or other obstruction that mended that a flexible couplingbe installedbetween will interferewith the flow of air through the fan blade the air dischargevalve outlet and mainairdistribu - flywheel . See Table 1for recommended distances . The tion lineto allowfor vibration . area should allow space on all sides for air circulation and for ease of normal maintenance . To remove entrained dirt , oil andwater , installsepara - tor in the main distribution line , a sufficientdistance from the compressor . This will allowthe air to cool to room temperature before passing through the separa - tor . The compressor outfit must not be op - erated in any confined area wheres - Additional separatorsorfilter may be useddepend - heat from the outfit can not readily e ing on the application . cape . Damage to the outfit may result . NOTE The compressor crankcase and head are designed with fins which allow for proper cooling . Clean or blow For underground installation , bury air lines below the frost line and avoid offthe fins and any other parts of the compressor out - fit that collect dust or dirt . A clean compressor runs pockets where condensation can cooler and provides longer service . Do not place rags , gather and freeze . Apply pressure be - containers , or other matedal in or against the belt guard fore underground lines are covered which will obstruct ventilation openings necessary for to make sure all pipe joints are free from leaks . proper compressor operating temperatures . AIR LINE PIPING ( STATIONARY COMPRESSOR OUTFITS ) Table 2 Pipe Sizes for Compressed Air Lines AIR LENGTH OF PIPE LINES IN FEET cfm 25 50 75 100 150 200 250 300 The use of plastic pipe , soldered joint , or failure to insure system capabilityn 1 - 5 1 / 2 1 / 2 1 / 2 1 / 2 1 / 2 1 / 2 1 / 2 142 of flex joints and flexible hose ca 10 1 / 2 1 / 2 1 / 2 1 / 2 1 / 2 1 / 2 1 / 2 142 result in mechanical failure , property 15 1 / 2 3 / 4 3 / 4 3 / 4 3 / 4 3 / 4 3 / 4 3 / 4 damage , and serious injury . 20 3 / 4 3 / 4 3 / 4 3 / 4 3 / 4 3 / 4 3 / 4 3 / 4 Plastic or PVC pipe is not designed for 25 3 / 4 3 / 4 3 / 4 3 / 4 1 1 1 1 usewith compressed air . sRegardlessstice 30 3 / 4 3 / 4 3 / 4 1 1 1 1 1 of its indicated pressure rating , pla pipe can burst from air pressure . U 35 3 / 4 3 / 4 1 1 1 1 1 1 only metal pipe for air distribution lines . 40 3 / 4 1 1 1 1 1 1 50 1 1 1 1 1 1 1 1 A typical compressedairdistribution systemasshown 60 - 70 1 1 1 1 1 - 1A 1 - 1 / 1 - 1A 1 - _ A in Figu re 4 , page 10 should be of sufficientpipe size 80 - 1001 - IA1 - I / _ I - I , _ I - 1 / _ I - Ih 1 - Y . , 1 - V21 - I / 2 to keep the pressure drop between the supply and point of use to a minimum . All pipes and fittings used Pipe sizes are in inches must be certifiedsafefor the pressures involved . PAGE 9
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FEEDER LINES SLOPEWITH AIR FLOW AIR FLOW \ AIR FLOW _ r - - _ MAIN DISTRIBUTION AIR LINES SLOPE PIPE IN DIRECTION OF AIR FLOW . AIR WATER CONDENSATE FLOWS SUSAGE ALONG So'PrOM OF PIPE TO REGULATOR LEG DRAIN LEGS , PREVENTING IT FROM ENTERING FEEDER / N LUBRICATOR LINES . OFRAP DRAIN T TRAPS FILTER FLEXIBLENG MOISTURE SEPARATOR COUPLI AND TRAP AIR DISCHARGE VALVE COCK VALVE VIBRATION PADS Figure 4 . Typical Compressed Air Distribution System PAGE 10
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OPERATION The unloader valve , Figure 6 , iscontrolledbytank pres - Operator Controls sure . Compressors with unloaders run continuously and maintain air pressure within set limits . At maxi - The unloader valve for the operation of the gasoline mumtank pressurethe unloadervalve opens andthe compressor outfit is located between the compressor compressed air is exhausted to atmosphere . This pump and gasoline engine . The air discharge valve preventsthecompressorfrom continuallybuildingmore can be located on the end of the air tank . The safety pressureif airis not needed . When the tank pressure valve and pressure gauge are attached to the tank drops to a predetermined minimum pressure , the below the unloader . See page 7 . unloadervalveclosesandthe compressoragainbuilds upthe tank pressure . Pressure continuesto buildun - til maximum tank pressure is achieved . The cycle Unloader Valve then repeats itself . The unloader isused because frequent start - upsand stops are impractical with a gasoline engine . The unloadervalve is preset at thefactory . Never attempt Pressure loads beyond the design limits to make adjustments to the unloader valve . may cause tank rupture or explosion . Do not attempt to adjust , remove , or defeaty The toggle leveronthefront of the unloadervalveshould the unloader valve , or change and modif be pulled outor inthe horizontalposition when start - any pressure control device . If replace - ing upthe compressor . This prevents the compressor ment is necessary , the same rated valve must be used . from starting under load . Once the engine has reached full throttle , the lever should be pushed to the side , returning it to its original position to allow the com - pressor pump to build pressure in the air tank . Toggle Lever Figure 6 . Unloader Valve PAGE 11
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The unloaderthen reactivates the throttle control and accelerates the engine to fullthrottle . Over - pressurization of the air tank ADDITIONAL REGULATORS AND may cause tank rupture or explosion . CONTROLS The air tank is protected from over - pressurization by a safety valve . Do not eliminate , make adjustments or Since the air tank pressure is usually greater than substitutions to this device . Occasion - that which is needed , a separate regulatoris usually ally pull the ring on the safety valve employedto controlthe air pressureahead of any to make sure it operates freely . If it individualairdrivendevice . doesn't , the safety valve must be replaced . Innercooler safety evalves used on two stage outfits must b similarly checked . The safety valve , Figure 7 , is set at the factory to be The gasoline engine and air compressor pumps on all compressor outfits are pressure approximately 15 pounds higher than the shipped without oil Do not attempt toadd - ratedpressureof the outfit . Ifthe unloadervalve mal - operate for any reason without first functions and does notexhaustcompressedairauto - ing oil to the engine and compressorcan matically at maximum tank pressurethe safety valve pump crankcase . Serious damage willprotectthe airtank againstexcessive airpressure result from even very limited operation unless filled with oil and broken in by poppingoff at its preset pressure . correctly . Make sure to closely follow the initial startup procedures . Two stagecompressorswithunloadercontrolswillhave a safetyvalve on the intercooler , set50 to 55 pounds . NOTE The purpose of thissafety valve is to prevent the full The compressor outfit should be placed on a level surface in a dry , clean , well tank pressure building up inthe large , low pressure ventilated , area . Do not place any mate - cylinderor intercooler . rial on or against the belt guard . Thisor blocks ventilator openings necessary f proper compressor cooling . THRO'I - rLE CONTROL 1 . Remove the oilfill plugson the gasoline engine and air compressorpump and slowly addoil A gas saving throttle control has been incorporated untilthe unitsare full . Refer to the " Gasoline on somecompressor outfits . Duringnormaloperation , Engine OwnersManual " for recommended oils as maximumtank pressureis obtained , the unloader and fill capacitiesfor the engine . The compres - exhausts compressed air and activates the throttle sor pump holdsapproximately60 fluid oz . . control of the engine . The throttle control holds the engine at a factory set idlingspeed untilair pressure inthe tank dropsto reset orminimumtank pressure . TWO STAGE COMPRESSOR UNITS Viscosity Chart Recommended Oil Room or Ambient ( API SG / CD Heavy Duty ] Temperature SAE20 Below 20 ° F SAE30 Above 32 ° F Figure 7 . Safety Valve Crankcase capacity equals approximately 60 fluid ounces , 2 . The air compressor outfitis readyforuse . PAGE 12
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3 . Periodicallycheck the compressoroutfitduring 4 . Check the enginefuel tank level . Add fuel if necessary . the firstfew days of operation to make sure the compressor outfit is runningsmoothlyand Before starting the compressor outfit , check the allcontrolsare operatingproperly . following : NOTE After the compressor has been in . Close the airdischargevalve . operation for 2 to 3 hours , tighten the 6 . compressor head bolts . Setthe toggleleverof the unloadervalve in the vertical positionto relieve compressor Torque two stage compressor head head pressure . bolts to 35 foot - pounds using a criss - cross pattern when tightening . 7 , Move the control lever orchoke levertothe CHOKE position . 8 . Turn the engine lever or key switch to the BREAK - IN PROCEDURES ON position . NOTE Perform steps 1 - 8 of the Daily StartupProcedures . If the engine is warm or the air tem - Open the airdischargevalve . perature is high , move the hcontrole lever or choke lever away from t CHOKE position as soon as the engine starts . DALLY STARTUP PROCEDURES . Start the compressor outfit by pulling the Performthe followingchecks beforestartingthe starterhandle or by depressingthe starter compressoroutfit . button . Returnthe toggle leveronthe unloader valve to the horizontalpositionand allow 1 . Ensurethat nothing is blocking the belt outfitrunfor 10 minutes withoutbuildingany guard airopenings . pressure . Check that the unloader exhausts 2 . Pullthe dng on the safetyvalve to make air at maximum tank pressure . surethe valve moves freelyand smoothly . 3 . Checkthe engine and compressoroil levels . Add oil if necessary . If these break - in procedures are not followed , premature pump failure may result and void your warranty . Gasoline is extremely flammable and explosive . Refuel in a well ventilatedgine 10 . Check the following : area with engine stopped . Allow en to cool before refueling . a . Make sureall controlsare operating Do not smoke or allow flames or sparks in correctly . Refer to the " Operator Controls " the area where the engine is refueled or section of this manual . A separate where gasoline is stored . gasoline engine instructionmanual is Do not overfill the tank and make sure provideddetailingengineoperation . the filler cap is securely closed after b . Check allair lines , fittings and pipes for refueling . Be careful not to spill fueledd , leaks . Even minor leaks can cause the when refueling . Fuel vapor or lspille fuel may ignite . If any fuel is spil compressorto overworkresultingin make sure the area is dry before prematurebreakdown orunsatisfactory starting the engine . performance . PAGE 13
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c . Check for excessive vibration and noise . 2 , Turn the engine lever or key switchto the OFF Correct any defects found . position . . d . Check for oil leaks . Correct any leaks Close the airdischargevalve . found . 4 . Remove airtool oraccessory . 5 . SHUT DOWN PROCEDURES Open outlet valve or regulator to allow air to slowly bleed from the tank . Close the outlet valve or regulator when the tank pressure is To stopthe engine in an emergency , turn the engine approximately20 psig . ON / OFF lever or key switchto the OFF position . Un - der normalconditions , use the following procedures . 6 . Drainwater from tank . 1 . Allow the tank pressure to buildto maximum and the engine to throttledownto idle speed . MAINTENANCE NOTE Toensure efficientoperationand longer life of the air Drain and refill the compressor pump compressor outfit a routine maintenance schedule crankcase after the first 100 hours of shouldbe prepared and followed . The followingrou - operation . Add approximately 60 oz . . tine maintenance scheduleis geared to an outfitina to pump . normalworkingenvironment operatingona daily ba - sis . If necessary , the scheduleshould be modifiedto Drain and refill the gasoline engine crankcase suitthe conditionsfound withyour compressoroutfit . after the first20 hoursof operation . See " Gasoline The modificationswill depend upon the hoursof op - Engine Owners Manual " forenginecrankcase eration and the working environment . Compressor capacity . outfitsinan extremelydirtyand / orhostileenvironment will require a greater frequency of all maintenance 2 . Drain water from the air tank and any checks . The maintenance label mounted on the air moisture separatorsortrensformers . tank also liststhe required maintenance checks . 3 . Check forany unusual noiseand / or vibration . Foradditionalmaintenanceinstructionsr , ecommended oil andfuel onthe gasoline engine , refer to " Gasoline 4 . Manually check the safety valve to make sure Engine OwnersManual " . it is operatingproperly . 5 , Check the conditionof the aircleaner on the ROUTINE MAINTENANCE SCHEDULE gasoline engine . Clean and / or replace as necessary . DAILY . Check the gasoline engine's fuel level . Add fuel ifnecessary . 1 . Check the gasoline engine and aircompressor 7 . Inspect for oil leaks and repair any leaks found . pump oil levels ; add if necessary . PAGE 14
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WEEKLY CLEANING THE AIR COMPRESSOR OUTFIT 1 . Clean and inspect the compressor air intake filter ; replace if necessary . The external components of the compressor outfit shouldbe cleaned at least oncea week . The aircom - 2 . Inspect condition of drive belt ; replace if pressorcrankcase and head are designed with fins necessary . whichallow for propercooling . Clean orblowoff fins and any other parts of the outfit that collect dirt or 3 . Clean outside partsof the compressoras well as dust . A clean compressor runs cooler and provides the engine inorderto maintain efficientcooling . longer service . CHECKING AND CHANGING OIL MONTHLY 1 . Check the alignment of the engine pulley to the flywheel if necessary , alignto within 1 / 16 inch . Overfilling with oil will cause premature 2 . Inspectfor and correctany oil leaks . air compressor failure . Do not overfill . 3 . Check drive belttansion adjust if necessary . 1 . Check oil level in compressor crankcase before each use . 4 . inspect air lines and fittingsfor leaks ; correct as For two stage compressorsthe oil levelshould necessary . be to the middle of the oil sight glass . NOTE EVERY 50 HOURS OF OPERATION The compressor pump oil must be changed after the first 100 hours of 1 . Clean the gasolineengine air cleaner . operation . EVERY 100 HOURS OF OPERATION Changing Oil : 1 , Drain and refillthe gasolineengine crenkcase 1 . Remove the oilfill and drain plugs . Collectthe oil with clean oil . ina suitablecontainer . 2 , Clean and setgap or replace spark plug . 2 . Replace the oil drain plugand refillthe crankcase with recommended oil . Refertopage 14of this 3 . Clean fuelsediment cup . manual for recommended compressoroil . NOTE It is important to maintain the proper EVERY 500 HOURS OF OPERATION oil level . A low oil level reduces proper cylinder wall lubrication and increases ring wear . 1 . Drain and refill compressorcrankcasewith clean oil . 3 , Replace the oil fill plug . 4 . Startthe engine and run the compressoroutfit EVERY 2000 HOURS OF OPERATION , OR IF for several minutes . Shutthe compressordown A PROBLEM IS SUSPECTED and check the oil level . If necessaryadd more oil . 1 . Check condition of compressor pump intake and exhaustvalves . Replace if damaged or wornout . PAGE 15
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CHECKING AND CHANGING AIR Open the drain valve . Continue operating outfituntiln allmoistureis removedfrom the tank . Closethe drai INTAKE FILTER valvetightly . NOTE NOTE Keep the air filter clean at all times . Do not operate compressor outfit when If the draincock is clogged , release the filters are removed . the air pressure in the tank . Remove the drain valve and clean or replace . Apply sealant to the threads before The conditionof the air intakefiltershouldbe checked reinstalling the drain valve . once a week . A dirty air intake filter will not allow the compressortooperate atfull capacityandwill increase oilusage . CHECKING AND ADJUSTING BELT When the airfilter becomes dirty , oily , or coveredwith TENSION paint overspray it must be replaced . To check and / or replace the air intake filter , remove the screw securing the filter assembly to the air compressor pump . Re - move the filter . Inspect condition of filter ; replace if necessary . Serious injury or damage may occur if parts of the body or loose items get caught in moving parts . Never eoperatelt NOTEe the compressor outfit with the b Felt and foam intak filters can be guard removed . The belt guard shouldug washed in non - explosive solvent . only be removed after the spark pl Allow to dry and reinstall . DO NOT OIL wire has been disconnected . INTAKE FILTERS . The drive belt shouldbe kept in propertension as a loose beltwillslip and wear faster . An over tightened DRAINING WATER FROM AIR TANK belt will place an excessive load on the engine and compressor pump bearings causing prematurefail - ure . The belt tensionshould be checked as follows : 1 . Disconnect the spark plug wire and drein all air Water will condense in the air tank . pressure fromthe air tank . If not drained , the water will ecorrodened and weaken the air tank . A weak 2 . Removethe beltguard . tank may explode or rupture causing personal injury . Drain the tank as instructed below . 3 . Loosen all enginemountinghardwareand slide the engine either toward oraway from the Water should be drained from the air tank daily . If compressor untilcorrect belttension is achieved . humidity is highthe tank shouldbe drained at regular intervals duringthe day . Operate the compressor outfit to allow 15 to 20 psi air pressure inthe tank . PAGE 16
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4 , Holdthe belttension untilthe engine mount - ing hardwarecan betightened . DRIVE BELT DOWNWARD FORCE 5 . Ensure that the belts are centered on the enginepulleyand compressorflywheel . NOTE Once the engine has been moved from its factory set location the engine pulley must align to within 1 / 16 inch to the compressor flywheel . . Torqueengine mountingboltsto 20 + 3 foot pounds . COMPRESSOR 7 . Reinstallthe belt guard . FLYWHEEL 8 . Connect the spark plug wire . Figure 8 . Checking Belt Tension On compressors equipped with standardV - belts , each beltshould deflect 1 / 4 " at the midway point between the engine pulleyand flywheel when a downwardforceof 4 pounds , orequivalentfinger pressure , is applied at the midway point . Refer to Figure8 . SERVICE INSTRUCTIONS Moving parts , unexpected engine start - up and compressed air can cause serious injury . Always disconnect the spark plug wire and relieve pressure from the air tank before performing any of these service procedures . Never operate the air compressor with the belt guard removed . 4 . REPLACING DRIVE BELT Remove the beltand replacewitha new one . On compressor outfits with matched V - belts , both belts must be replaced at the same The gasolineengine is mounted to the tank assem - time . blysaddle . By looseningengine mountinghardware , the engine can be moved to allow foreasy removal NOTE of the belt . Replace the drive beltas follows : The belts should be centered on the flywheel and engine pulley . Once 1 . Disconnect the spark plug wire and drain all air the engine has been moved from its pressure from the tank . factory set location , the engine 2 . Removethe beltguard . pulley mustalign to within 1 / 16 inch of the flywheel . 3 . Loosenthe enginemounting hardwareand slide the enginetoward the compressor . PAGE 17
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REPLACING DRIVE BELT ( cont'd ) 6 . Reinstall the drive belt . Make sure the belt is centered onthe engine pulleyandflywheel . 5 . Slide the engine back intoits originalposition 7 . Slide the engine back into its originalposition andadjust the belttension , Figure 8 . and adjust the belt tension , Figure 8 . Forcompressors equipped with standardV - belts , Forcompressorsequipped with poly - V - belts , the the propertension for each belt is approximately proper tension is approximately1 / 4 inch belt 1 / 4 inch beltdeflectionmeasured midway between deflection measured midway betweenthe engine the engine pulley and flywheel when a 4 pound pulleyandflywheelwhen a 3 pound downward downward force , orequivalent finger pressure , is force , or equivalentfingerpressure , is applied at applied at that point . that point . 6 . Hold the belt tension until the engine mounting For compressorsequipped with standardV - belts hardware can be tightened . the proper tension for each belt is approximately 1 / 4 inchbeltdeflection measured midwaybetween 7 . Torque engine mounting bolts to 20 + 3 foot - the engine pulleyand flywheel when a 4 pound pounds . downwardforce , orequivalentfingerpressure , is 8 . Reinstall the belt guard . applied at that point . 9 . Connect the spark plug wire . 8 . Hold the belt tension untilthe engine mount - ing hardwarecan be tightened . 9 . Torque the engine mounting boltsto 20 + 3 foot - pounds . 10 . Reinstallthe belt guard . ENGINE PULLEY AND FLYWHEEL ALIGNMENT 11 . Connect the spark plug wire . The engine pulley and flywheel must be alignedto prevent excessivewear of the drivebelt andto keep CHECK VALVE INSPECTION AND CLEANING the belt from comingout of the pulleyand flywheel grooves . Align the beltsas follows : Remove and inspectthe check valve at least once a year and more often ifthe compressoris heavily used . Moisture and other contaminates inthe hot compressedairwill cause an accumulationof Serious injury or damage may occur if carbon - likeresidueonthe workingparts . Ifthe valve parts of the body or loose items get has heavy carbonbuild - up , itshouldbe replaced . caught in moving parts . Never roperated Use the followingprocedure to inspect , clean , or the compressor outfit with belt gua replacethe checkvalve : removed . Remove belt guard only after the spark plug had been disconnected . 1 . Disconnect the spark plug wire and re - lease all air pressurefrom the air tank . 1 . Disconnect the spark plug wire and drain all pressurefrom the air tank . 2 . Loosen the top and bottom tube nuts and removethe outlettube . 2 . Remove the belt guard . 3 . Unscrew the check valve ( counterclock - 3 . Loosen all engine mounting hardware and wise ) from the air tank using a socket slide the enginetoward the compressor . Re - wrench . move the drive belt . 4 . Check that the valve and disc moves freely 4 . Loosenthe engine pulleyset screw and move inside the check valve and that the spring the pulley toward or away from the engine until holdsthe discinthe upper closed position . the pulley aligns withthe flywheelwithin 1 / 116 The check valve may be cleaned witha inch . solvent . 5 . Torque the engine pulley set screw to 75 + 5 5 . Apply pipe sealant to the check valve threads . inch - pounds . PAGE 18
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6 . Reinstatlhl echeckvalveD . ONOTOVER - TIGHTEN . Many solvents are highly flammable and a health hazard if inhaled . Always observe the solvent manufacturers SERVICINIGNTAKEANDEXHAUSVTALVES safety instructions and warning . e . Theintakeandexhausvtalvesaswellasthevalve Clean carbon deposits in head cavitiesand valves plates with lacquer thinner or platesandcylindehreadwill , overaperiodoftime other suitablesolvent . accumulatreesidue of carbon - like materialon their surfaces . The material will decrease the efficiency f . Remove the intakeand exhaust valve of the compressor . These componentsshouldbe assemblies fromthe valve plate . Clean and inspected , whenever a problem is suspected , and inspect the valves , and valve retainers . cleaned or replacedwith new parts . Use the follow - Replace any defective componentsas ing procedureto inspectthe parts . necessary . g . Reassemble the intake and exhaust valves . NOTE During service or repair activities Do not use gasket cement on anye always disconnect the spark plug wire gasket surface as this may clog th before attempting repair maintenance compressor valve cavities and flow on compressor outfit . Make sure the areas . pressure is released from the air tank . h . Reinstallthe valve plate , Use a new 1 . Disconnect the sparkplugwire and drain valve plategasket . all air pressure fromthe air tank . 2 . Service two stage compressor valves Install the cylinder head . Use a new as follows : head gasket . Snug the mountingscrews a . Remove the screws securingthe tight then torque to 35 foot - pounds intercoolerto the cylinder head and usinga cdss crosspattern when torquing . removethe intercooler . j . Installa new after cooler gasket . Secure b . Disconnect the outlet linefrom the the aftercoolerwiththe mountingscrews aftercooler . removed . c . Remove the screws securingthe k . Connectthe outlet line to the aftercooler . aftercooler to the cylinder head and remove the aftercooler . I . Installnew intercoolergasketsand securethe intercoolerwith the mounting d . Removethe hardware securingthe screwsremoved . cylinderhead and remove the cylinderhead and valve plate . 4 . Connect the sparkplug wire . PAGE 19
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TROUBLESHOOTING GUIDE Performing service checks or repairs may expose moving parts , or compressed air sources . Personal injuries may occur . Prior to attempting any service check or repairs , remove the spark plug wire and bleed off all air pressure . Never operate the outfit with the belt guard removed . Repairs should be preformed by an Authorized Service Center personnel only . TROUBLESHOOTING CHART PROBLEM CAUSE CORRECTION Gasoline Engine will not run . The gasoline tank is empty . Fillthe tank with gas . ( Consult the " Gasoline Engine Owners Manual " for The choke is notset properly . Reset the choke . Remember , a Manufacturer's Service Centers warm engine requiresless for warranty , repairs and service chokingthan a cold engine . parts . ) Improper fuel mixture . Adjust the fuel mixture . The unloadervalve toggleleveris Place unloadingvalve togglelever in a horizontalposition . ina vertical position . If any fuel is spilled , make sure the area is dry before testing the engine . Fuel vapor or spilled fuel may may ignite . No sparkfromthe spark plug . Remove the spark plug , clean and adjustgap or replace . Sparkplug disconnected . Connect spark plug . PAGE 20
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TROUBLESHOOTING CHART ( Continued ) PROBLEM CAUSE CORRECTION Clean . RoughOperation of Gasoline Cloggedfuel line . Engine . ( Consult the " Gasoline Water in fuel . EngineOwners Manual " for Be sure outfit is adequately Manufacturer'sServiceCenterfor protectedfrom the elements so warranty , repairsand service as to preventwater seepinginto parts . ) system . Faulty chokecontrol , Adjust . See engine manufacturer's instructions includedwith engine . Impreper fuel mixture . Use onlyfuel recommendedby engine manufacturer . See manufacturer'sinstructions . Check all connectionsto insure Loose ignition systemconnec - tions . tightness . Air leaks incarburetor or mani - Check to be sureall connections fold connections . are tight , Insufficientair andtoo much Restricted air intake Clean filteror properlysize pipe to the remote intake . compressor " ON " time . Check for source of leak and Air leaks in system . correct . Undersized unitfor air require - Replace withlargerunitor ment . purchase a second outfit . Worn orcarbonizedvalves . Replace . Flywheelwobbles . Set screw or bolt not tight Tighten . enough . Air leaks . Tube fittingsloose . Tighten fittings with audibleleak and check fittingsunderpressure withsoapy water solution . Leak at welds Replace airtank . Do not drill Into , weld or other - wise modify air tank or tank will be weakened . Tank must be replaced . If safety valve or unloader valve replacement is necessary , a part with the same rating must be used . PAGE 21
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TROUBLESHOOTING CHART ( Continued ) CORRECTION PROBLEM CAUSE Air leak in safetyvalve , Operate safety valve manually by Air leaks ( cont ) pullingon ring . If valve stillleaks , it should be replaced . Defective checkvalve . A defective check valve results in a ( Unloader vaive ) constant air leak , back through the unloadervalvewhenthereis pressure inthe air tank and the compressoris notrunning . Turnthe engineoff ; move the unloadervalve toggleleverto the verticalposition . Ifair leaksoutof the tank throughthe unloadervalve , clean or replacethe checkvalve . ( DO NOT OVERTIGHTEN ) . Prolonged excessive use of air . Decrease amount of air usage , Low Discharge Pressure Restrictedcheck valve . Remove and clean , orreplace . Restrictedair intakefilter . Clean orreplace air intakefilter . Air leaks . Tighten fittings . Hole in hoseor air piping . Checkand replace if required . Faulty pump . Repairor replace . Loose pulley . Tighten pulley set screw . Knocking Check oil level and maintainat Low oil level ( compressorpump and / or gasolineengine ) . prescribedlevel . Restricted check valve . Remove and cleanor replace . Followoil recommendationslisted Wrong oil used . inthe " Gasoline Engine Owners Manual " . Compressor and / orengine bolts Check all bolts and tightenas loose . required . Excessive carbon deposits in head . Removethe head andvalve plate . Clean top of pistonand bottom of valve plate . Reassemble usingnew gasket and torque screwsto 35 foot - pounds . PAGE 22
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TROUBLESHOOTING CHART ( Continued ) PROBLEM CAUSE CORRECTION Knocking ( cont'd ) Flywheelloose . Make sureflywheelistightbytight - ening screw . Torquescrewto 20 + 5 - 0 foot - pounds . Loose belt . Tighten belt . Restrictedair intake . Excessive Oil Consumption Replace . Compressor overworked . Reduce air consumption or add additional air compressorto take upload . Poor qualityor automotive multiviscosityoil used . Drainpump and replacewith new oil . Excessive engineorcompressor Checkpulleyand / orflywheel forlat - shaft end play . eral movements . Contact engine manufacturer for repair , or DeVil - bissif a compressor problem ex - ists . CompressorOver heating Compressor overworked . Reduceairconsumption oradd ad - ditionalair compressorto take up load . Check valve restricted . Clean . Clean . Dirty compressor . Use remote air intake . Highambient temperature . Worn orcarbonizedvalves . Replace . Compressortoo closeto wall . Relocate . Checkforsourceor leaksandcor - Air leaks in system . rect . Under sized unit for air require - Replace with a larger unit , ment . Unloader notoperating . Replace . Remote air intake pipe to small Replace remoteairintakepipping . or restricted . Compressor should not exceed Insufficient " OFF " time . Com - 50 % run time , which is maximum 30 min / hr . Check for source of pressoris runningalmost continuously . leaks and correct , or replace with largercompressor , PAGE 23
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TROUBLESHOOTING CHART ( Continued ) PROBLEM CAUSE CORRECTION Restrictedair intake . CompressorOverheating ( Cent ) Remove and clean orreplace air filter . Improperlevel and / orgrade of oil Check for proper oillevelsand used . recommended oilusage . Damaged valves ( intakeand / or Repairor replace as necessary . exhaust ) . Excessive BeltWear Loose belt . Adjust belt tension . Pulley misalignment . Align pulley to within 1 / 16 inch of the flywheel . Loose pulley . Check forworn key or pulley bore . Also check for bent engine shaft . Replace or repairas necessary . Tighten pulley set screw orbolt . Reduced Air Delivery Compressor valvesleaking , Replace . stickingorcarboned up . Worn rings . Replace . Head gasket leaking . Tighten or replace gasket . Restrictedair intake . Clean orreplace . Loose drivebelt . Tighten butdon'tovertighten . Water inCrankcase ; oil appears Unit notreachingproperoperat - Consult withfactory or dealer . milky in color . ingtemperature becausethe compressorrunsfrequently and is oversizedfor the air require - ment . Humid operating conditions . Relocate compressoroutfit . Change oilfrequently . Avoid cylinderrustingand ringwear . Excessive Water in Air Receiver Condensation inthe air receiver . This is a normal resultof com - Tank . pressing air and notdue to faulty equipment . This conditioncan be correctedby drainingthe air receiverdaily . PAGE 24
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COMPRESSOR / PUMP DIAGRAM AND PARTS LIST PAGE 25
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Air Compressor Diagram Detail A T _ QUE TO 1 _ 2 F _ ÷ I . B . 31 21 22 23 24 26 27 25 38 34 5 33 12 18 PAGE 26
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Parts List KEY pART NUMBER NO . SSF - 3121 - ZN Engine bolt ( 4 used ) 1 11 HP Gas Engine * 2 Nut ] Sleeve 5 / 8 " ( 2 used ) 3 SSP - 7824 Outlet Tube AC - 0606 - 1 4 Elbow SSP - 6461 5 SSP - 1144 Bushing 6 ABP - 4592 Two - Stage Compressor Pump 7 8 SSF - 3159 Pump bolt ( 4 used ) Elastomer Bushing ( 5 used ) 11 CAC - 1011 Belt Guard Inside 12 CAC - 1334 - 1 SSN - 51 Washer ( 5 used ) 13 14 91895680 Screw ( 6 used ) Belt Guard Outside 18 CAC - 1335 DAC - 306 19 Strap , Pump CAC - 1343 - 1 Strap 21 Washer ABP - 9134350 22 Screw SSF - 3161 23 24 GA - 359 Gauge Tee 25 SSP - 6820 TIA - 4200 26 Safety Valve 27 SSP - 454 Nipple Unloader Valve AC - 0509 28 Screw 29 SSF - 551 - ZN Elbow ( 2 used ) 1 / 8 " NPT 3O SSP - 535 AC - 0510 Throttle Control Assembly 31 CAC - 1341 Bushing ( includes 3 screws ) 32 SST - 106 Key 33 34 C - PU - 2886 Pulley BT - 301 Belt ( 2 used ) 35 Stiffener Plate 36 CAC - 1346 - 1 38 CAC - 1337 Engine Strap Not Shown SSF - 8131 Beltguard nut ( 4 used ) Beltguard screw ( 4 used ) SSF - 953 - ZN Drain Valve SS - 2707 * See Engine Manual for Engine Information . PAGE 27
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Compressor Pump Diagram V 2 6 8 10 11 PAGE 28
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Parts List KEY NO . PARTS NUMBER DESCRIPTION 1 ABP - 8226501 Hardware Kit 2 ABP - 5961405 Head 3 ABP - 5940055 Valve Plate Kit 4 ABP - 5950057 Gasket Kit 5 ABP - 5281100 Filter 6 ABP - 5981000 Filter Assy . ( Includes # 5 ) 7 ABP - 9024011 Oil Filter Plug 8 ABP - 9022003 Sight Glass 9 ABP - 9013013 Split Bearings 10 ABP - 9004009 Flywheel Washer 11 ABP - 9110022 Flywheel Screw 12 ABP - 5000101 Flywheel 13 ABP - 5962020 Intercooler • 14 ABP - 8226502 HP Running Gear Kit 15 ABP - 8227093 HP Ring Kit 16 ABP - 8227092 LP Ring Kit • 17 ABP - 8226503 LP Running Gear Kit NOT SHOWN ABP - 9049020 Intercooler Safety Valve e lncludes rings , piston pin , snap rings , rods , oil dipper and split bearings . PAGE 29
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LIMITED WARRANTY ONE YEAR FROM DATE OF PURCHASE All merchandise manufactured by DeVllbiss Air Power Company / ExCell Manufacturing is warranted to be free of defects in workmanship and material which occur during the first year from the date of purchase by the original purchaser ( initial user ) . Products covered under this warranty include : air compressors , * air tools , accessories , service parts , pressure washers , and generators used in consumer applications ( i . e . , personal residential house - hold usage only ) . Air compressors , * air tools , accessories , service parts , pressure washers , and generators used in commercial applications ( income producing ) are covered by a gO day warranty . DeVilbiss Air Power / ExCell Manufacturing will repair or replace , at DeVilbiss / ExCell's option , products or compo - nents which have failed within the warranty period . Repair or replacement , and service calls on 60 and 80 gallon air compressors , will be handled by Authorized Warranty Service Centers and will be scheduled and serviced according to the normal work flow and business hours at the service center location , and depending on the availability of replacement parts . All decisions of DeVllbiss Air Power Company / ExCell Manufacturing with regard to this policy 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 ) : Retain original cash register sales receipt as proof of purchase for warranty work . Q Use reasonable care in the operation and maintenance of the product as described in the Owners Manual ( s ) . [ 31 Deliver or ship the product to the nearest DeVilbiss Air Power / ExCell Manufacturing Authorized Warranty Service Center . Freight costs , if any , must be paid by the purchaser . Q Air compressors with 60 and 80 gallon tanks only will be inspected at the site of installation . Contact the nearest Authorized Warranty Service Center , that provides on - site service calls , for service call arrangement . Q If the purchaser does not receive satisfactoryresults from the Authorized Warranty Service Center , the purchaser should contact DeVilbiss Air Power Company / ExCell Manufacturing . THIS WARRANTY DOES NOT COVER : Q Merchandise sold as reconditioned , floor models and / or display models . Any damaged or incomplete equip - ment sold " as is " . [ 3 Merchandise used as " rental " equipment . Q Merchandise that has become inoperative because of ordinary wear , misuse , treeze damage , use of improper chemicals , negligence , accident , improper and / or unauthorized repair or alterations including failure to operate the product in accordance with the instructions provided in the Owners Manual ( s ) supplied with the product . * Air Tools : O - Rings and driver blades are considered ordinary wear parts , therefore , they are warranted for a period of 45 days from the date of purchase . An air compressor that pumps air more than 50 % during a one hour pehod is considered misuse because the air compressor is undersized for the required air demand . Maximum compressor pumping time per hour is 30 minutes . Merchandise s _ d by DeVi _ bissAir P _ wer _ ExCe _ lManufacturing which has been manufactureq by and identi _ ed as the product of another company . The product manufacturer's warranty will apply . [ 3 Repair and transportation costs of merchandise determined not to be defective . _ 1 Cost associated with assembly , required oil , adjustmentsor other installation and sfart - up cost . Q ANY INCIDENTAL , INDIRECT ORCONSEQUENTIAL LOSS , DAMAGE , OR EXPENSE THATMAY RESULT FROM ANY DEFECT , FAILURE OR MALFUNCTION OF THE PRODUCT . Some states do notallowthe exclusionor limitation of incidentalor consequential damages , so the above limitationor exclusionmay not apply to you . [ 3 IMPLIED WARRANTIES , INCLUDING THOSE OF MERCHANTABILITYAND FITNESS FORA PARTICULAR PURPOSE , ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE . Some statesdo not allow limitationson how long an implied warranty lasts , so the above limitationsmay not apply to you . Ddq / . EBS A / R m mmMmy Form : 8P * 100 - F - 10 / 28 / 97 FA , V _ f - _ gO - 8884 _ t PAGE 30
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Service Notes PAGE 31
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GENERAL OPERATION AND PARTS FOR GASOLINE COMPRESSOR OUTFITS MODEL NO . DACE - 7161 - 2 Call our Toll Free Number 1 - 800 - 888 - 2468 , Ext 2 , then 1 , to obtain the location of the nearest Authorized Service Center for ordering repair parts and for warranty repairs . When ordering repair parts from your local Authorized Service Center , always give the following information : • Model number of your product • Part number and description of the item you wish to purchase WARRANTY Attach Sales Receipt Here . This product is covered by the DeVilbiss Retain OriginalSales Receipt as Proof one year limited warranty . The warranty of Purchase for Warranty Repair Work . can be found in the General Manual oris available upon request . DeVllblss Company Air Power • 213 Indusb - ial Or , • Jackson , TN 38301 - 9615