Electric Wheeled Portable - J

Electric Wheeled Portable Owner’s Manual
PO Box 1286
Johnstown, PA 15907
Phone: 814.532.4149
Fax: 814.532.4102
Revised: 4/15/2010
Introduction
Congratulations on the purchase of your new J-Air compressor! You can be
assured that this tool has been constructed with the highest level of precision and
accuracy. Each component has been rigorously tested by technicians to ensure the
quality, endurance and performance of this air compressor.
Improper operation or maintenance of this product could result in serious injury
and property damage.
The user of the air compressor must understand these instructions. Each person
operating the air compressor must be of sound mind and body and must not be
under the influence of any substance, which might impair vision, dexterity, or
judgment.
By reading and following the safety, operation, maintenance and troubleshooting
steps described in this manual, you will receive years of trouble-free operation.
The manufacturer reserves the right to make changes in price, color, materials,
equipment specifications or models at any time without notice.
Air Tank
The tank on your air compressor is designed and may be UM coded (for
units with tanks greater than 6 inch diameter) according to ASME Section
VIII, Division 1 rules. All pressure vessels should be inspected once every
two years. To find your state pressure vessels inspector, look under the
Division of Labor and Industries in the government section of a phone book.
If you have any questions or comments about this or any J-Air compressor,
call us at 1-814-532-4149.
The following conditions could lead to a weakening of the tank, and result in a
violent tank explosion:
1. Failure to properly drain condensed water from the tank can rust
and cause thinning of the steel tank. Drain tank daily or after each use.
If tank develops a leak, replace it immediately with a new tank or new
compressor outfit.
2. Modifications or attempted repairs to the compressor tank. Never
drill into, weld, or make any modifications to the tank or its attachments.
3. Do not modify the safety valve, or any other components that
control tank pressure. The tank is designed to withstand specific
operating pressures. Never make adjustments or parts substitutions to
alter the factory set operating pressures.
Inspection of Compressor
Inspect for signs of obvious or concealed freight damage. Report any damage to
the delivering freight carrier immediately. Be sure that all damaged parts are
replaced and any mechanical problems are corrected prior to the operation of the
air compressor. The air compressor serial number is located on the deck of the air
compressor. Please write the serial number in the space provided in the service
section for future reference.
Safety Instructions
Warning! Read and understand all instructions before operating this
compressor. Failure to follow all instructions listed below may result in electric
shock, fire and/or serious personal injury.
Attachments and Accessories
Exceeding the pressure rating of air tools, spray guns,
air-operated accessories, tires and other inflatables can
cause them to explode or fly apart, and could result in
serious injury. Follow the equipment manufacturers
recommendation and never exceed the maximum
allowable pressure rating of attachments. Never use
the compressor to inflate small low-pressure objects
such as children’s toys, footballs, basketballs, etc.
Save these instructions!
Warning: Some dust created by this product contains chemicals known to the
State of California to cause cancer, birth defects or other reproductive harm. Some
examples of these chemicals are:
• compounds in fertilizers
• compounds in insecticides, herbicides and pesticides
• arsenic and chromium from chemically treated lumber
Risk of Explosion or Fire
To reduce your exposure to these chemicals, wear approved safety equipment such
as dust masks that are specially designed to filter out microscopic particles. Avoid
inhaling vapors and dust, and wash hands after using and handling.
Always operate the compressor in a well-ventilated area free
of combustible materials, gasoline or solvent vapors. If sparks
1
from compressor come into contact with flammable vapors, they may ignite,
causing fire or explosion. If spraying flammable materials, locate compressor at
least 20 feet up wind from spray area. An additional length of hose may be
required.
Hot Surfaces
Touching exposed metal such as the compressor head, motor, or aftercooler can
result in serious burns. Never touch any exposed metal parts on compressor during
or immediately after operation. Compressor will remain hot for several minutes
after operation. Do not move the compressor while it is running. Hot motor parts
could cause burns contributing to the dropping of the compressor, damaging the
compressor and/or injuring the operator.
Store flammable materials in a secure location away from compressor. Restricting
any of the compressor ventilation openings will cause serious overheating and
could cause fire. Never place objects against or on top of compressor. Operate
compressor in an open area at least 3 feet away from any wall or obstruction that
would restrict the flow of fresh air to the ventilation openings.
Risk From Noise
Caution: Wear appropriate personal hearing protection
during use. Under some conditions and duration of use,
noise from this product may contribute to hearing loss.
Risk From Flying Objects
The compressed air stream can cause soft tissue damage to exposed skin and can
propel dirt, chips, loose particles and small objects at high speed, resulting in
serious injury. Always wear ANSI Z28.1 approved safety glasses with side shields
when using the compressor. Never direct air stream at people or animals. Use only
OSHA approved air blow guns.
Risk of Electrical Shock
Your air compressor is powered by electricity, if it is not used properly it could
cause electric shock. Never operate the compressor out-doors when it is raining or
in wet conditions.
Risk to Breathing
The compressed air from your compressor is not safe for
breathing! The air stream may contain carbon monoxide, toxic
vapors or solid particles. Never inhale air from the
compressor either directly or from a breathing device
connected to the compressor.
Never operate compressor with guards or protective covers
that are damaged or removed. Repairs by anyone other than
qualified personnel can result in serous injury or death by
electrocution. Any electrical wiring or repairs required on
this product should be performed by authorized service
personnel in accordance with national and local electrical
codes.
Spray materials such as paint, paint solvents, paint remover, insecticides, weed
killers, etc. contain harmful vapors and poisons.
Repair or replace damaged or worn cords immediately. The use of a ground
fault circuit interrupted (GFCI) outlet is recommended and may be required
in certain areas.
Note: Operate air compressor only in a well-ventilated area. Read and follow the
safety instructions provided on the label or safety data sheets for the material you
are spraying. Use a NIOSH/MSHA approved respirator designed for use with the
specified application.
J-Air does not recommend the use of extension cords as this can create power
loss and overheating of the motor. Use of an additional air hose is recommended
rather than an extension cord. If use of an extension cord is unavoidable, it should
be plugged into a GFCI found in circuit boxes or protected receptacles. When
using an extension cord, observe the following:
Risk From Moving Parts
Always turn off the compressor, bleed pressure from the air
hose and tank, and disconnect from power source before
performing maintenance or attaching tools and accessories.
Keep your hair, clothing, and gloves away from moving parts.
Loose clothes, jewelry, or long hair can be caught in moving
parts. Air vents may cover moving parts and should be
avoided as well. Do not remove the protective covers from this product. Never
operate compressor with guards or protective covers that are damaged or removed.
Never stand on the compressor.
2
1.5 Hp Motor
Rating
16 amp. 115V
8 amp. 230V
2 Hp Motor
Rating
20 amp. 115V
9 amp. 230V
temporary adapter should be used only until a properly grounded outlet can be
installed by a qualified electrician. The green-colored rigid ear, lug, and the like,
extending from the adapter must be connected to a permanent ground such as a
properly grounded outlet box.
Extension Cord Chart
250
14 Ga.
16 Ga.
Length of Cord in Feet
500
1000
12 Ga.
10 Ga.
16 Ga.
14 Ga.
The adapter (C) is not for use in Canada.
Always store compressor in a horizontal position, on all four rubber mounts.
Length of Cord in Feet
250
500
1000
14 Ga.
12 Ga.
8 Ga.
16 Ga.
16 Ga.
14 Ga.
Grounding Instructions
In the event of a malfunction or breakdown, grounding provides a path of least
resistance for electric current to reduce the risk of electric shock. This tool is
equipped with an electric cord having an equipment-grounding conductor and
grounding plug. The plug must be plugged into a matching outlet that is properly
installed and grounded in accordance with all local codes and ordinances. Make
sure that the electrical circuit to which the compressor is connected provides
proper electrical grounding, correct voltage and adequate fuse protection. Do
not modify plug provided: if it will not fit the outlet, have the proper outlet
installed by a qualified electrician.
Features
Dual Control
This feature allows the compressor to operate in
either the constant run or the stop/start mode of
operation. The pilot valve is used to control the
compressor when operating in the constant run
mode. The pressure switch is used to control the
compressor when operating in the stop/start
mode. The mode of operation is determined by
the amount of time the compressor will be
required to supply air. If the demand for air is
infrequent, then the unit should be set up for stop/start operation to minimize
unnecessary run time and to save energy. If there is a frequent or extended demand
for air, and/or the unit is located in a remote area where access to the compressor
is difficult, the unit should be set up for constant run to minimize the number of
times the motor must start in an hour to ensure good motor life.
Improper connection of the equipment-grounding conductor can result in a risk of
electric shock. The conductor with insulation having an outer surface that is green
with or without yellow stripes is the equipment-grounding conductor. If repair or
replacement of the electric cord or plug is necessary do not connect the equipmentgrounding conductor to a live terminal.
Check with a qualified electrician or service personnel if the grounding instructions
are not completely understood or if in doubt as to whether the tool is properly
grounded.
Dual Voltage
Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole
receptacles.
This feature allows the compressor to operate in either
115- or 230-volt environments. The advantage of running
in the 230-volt range is a lower current draw. Lower
current draw may be necessary in areas with a poor power
source. Lower current also reduces operating costs. If
running in the 230-volt mode, the plug end must be
replaced with the appropriate plug.
Grounded tools intended for use on a supply circuit having a nominal rating less
than 150 volts: This tool is intended for use on a circuit that has an outlet that
looks like the one illustrated in Figure A. The tool has a grounding plug that looks
like the plug illustrated in Figure A. temporary adapter, which looks like the adapter
illustrated in Figures B and C, may be used to connect this plug to a 2-pole
receptacle as shown in Figure B if a properly grounded outlet is not available. The
3
Pilot Valve
Air Intake Filter
Pilot valves are used to maintain a constant pressure range while running
continuously. The pilot valve may be
used to operate a discharge line
unloader or an unloading device in the
compressor head. Unloading occurs
when the receivers (tanks) reach a
preset cut-out pressure. The pilot valve opens, actuating the unloading device that
allows the compressor to run in an unloaded mode. When the tank pressure drops
to the preset cut-in pressure, the pilot valve closes allowing the unloading device to
close and the compressor once again pumps into the tanks.
This filter (C) is designed to clean air entering the
pump. To ensure the pump continually receives a clean,
cool, and dry air supply this filter must always be clean
and filter intake must be free from obstructions.
Air Tank Drain Valves
The drain valves (D) are used to remove
moisture from the air tank after the air
compressor is shut off.
Tank Pressure Gauge
Manual Lock
The manual lock allows you to manually unload the compressor with air pressure in
the tank. To operate the unloading device in the head, rotate the flip lever to an inline position (dashed lines). Be sure to return lever to the loaded position after
starting the engine, or the pump will not operate at preset pressures.
The tank pressure gauge (E) indicates air
pressure in the air tank.
Regulated Pressure Gauge
The regulated pressure gauge (F) indicates the air
pressure available at the outlet side of the regulator.
This pressure is controlled by the regulator and is
always less or equal to the air tank pressure.
Pressure Switch
This switch (A) is used to start or stop the air
compressor. Moving the switch to the "ON"
position will provide automatic power to the
pressure switch, which will allow the motor to start
when the air tank pressure is below the factory
set "cut-in" pressure. When in the "ON (AUTO)"
position, the pressure switch stops the compressor
from charging air when the air tank pressure reaches
the factory set "cut-out" pressure. For ease of starting, this switch also has a
pressure release valve located on the side of the switch designed to automatically
release compressed air from the air compressor pump head and its discharge line
when the air compressor reaches "cut-out" pressure or is shut off. Moving the
switch to the "OFF" position will open the pressure switch contacts and stop the
air compressor.
Pressure Regulator
The regulator knob (G) controls the air pressure coming from the air tank.
Common Procedures
230 Volt Operation
• Ensure that cord requirements have been met.
• Ensure that motor requirements have been met.
• Ensure that dual voltage switch is in the proper position if so equipped.
Cord Requirements
If it is desired to operate your compressor at 230 volts it
is also necessary to replace the 115 volt plug, supplied
with the motor, with a UL/CSA listed plug suitable for
230 volts and the rated current of the compressor as
shown. A 230-volt plug as shown in the diagram at right
can be purchased at your local hardware or electrical
supply store. Follow the cord plug manufacturer
installation procedures, contact a qualified electrician or call J-Air at 814-532-4149
for proper procedures to install the plug. The compressor must comply with
all local and national electrical codes after the 230-volt plug is installed. The
compressor with the 230 volt plug should only be connected to an outlet having
the same configuration as the plug illustrated.
Safety Relief Valve
This valve (B) is designed to prevent system
failures by relieving pressure from the system
when the compressed air reaches a predetermined
level. The valve is preset by the manufacturer and
must not be removed or modified in any way.
4
Constant Run Mode
1. Turn compressor on. If the tank has been fully charged, bleed air from
the drain valves until pump starts.
2. Turn knob on top of pilot valve (H) counterclockwise until fully open.
Warning: Over loosening of this knob can cause damage to the
pilot valve.
3. Verify that the unit is in a constant run mode. If compressor shuts off,
adjust pilot valve to a lower cut out pressure until unit continues to run.
Motor Requirements
Units without a dual voltage switch
Warning: Make sure motor is disconnected from the power source before
rewiring motor leads. The motor supplied with your compressor is a dual voltage,
115- / 230-volt motor. If it is desired to operate your compressor at 230 volts,
single phase, it is necessary to reconnect the motor leads in the motor junction box
by following the instructions given on the motor nameplate. If unsure on how to
reconnect the motor leads contact J-Air or qualified electrician for proper
procedures to install the plug.
Note: For proper operation the pilot valve cut-out pressure must be below the
pressure switch cut-out pressure.
Warning: Make sure that the 230-volt cord plug end is properly connected
before operating in 230-volt mode.
Pilot Valve Cut-Out Pressure Adjustment
Note: Unit can remain running while performing this adjustment.
Units With A Dual Voltage Switch
Warning: Make sure that the 230 volt cord plug end is properly connected
before operating in 230 volt mode. The motor supplied with your compressor is a
dual voltage, 115/230 volt motor. If it is desired to operate your compressor at 230
volts, single phase, simply move the 115/230 volt switch to the 230 volt
position.
Warning: Aftercooler, pump head, and surrounding parts are very hot; do not
touch. (see Hot Surfaces)
Warning -Moving Parts: Keep your hair, clothing and gloves away from
moving parts. Loose clothing, jewelry, or long hair can be caught in moving parts.
Air vents may cover moving parts and should be avoided as well. Do not remove
the protective covers from this product.
Dual Control
NOTE: Unit must remain running while performing the following adjustments:
Warning: The pilot valve is brass, which is a soft metal. Do not over tighten
screw as threads can strip out.
Warning: Aftercooler, pump head, and surrounding parts are very hot; do not
touch. (see Hot Surfaces)
Warning - Moving Parts: Keep your hair, clothing and gloves away from
moving parts. Loose clothing, jewelry, or long hair can be caught in moving parts.
Air vents may cover moving parts and should be avoided as well.
Stop-Start Mode
1. Turn compressor on. If the tank has been fully
charged, bleed air from the drain valves until
pump starts.
2. Turn knob on top of pilot valve (H) clockwise
until fully closed.
Warning: Over tightening of this knob can
cause damage to the pilot valve.
3. Allow compressor to reach cut out pressure. If
compressor does not stop, drain the tank(s) until
compressor begins to charge the tank(s) and
readjust pilot valve knob.
1.
2.
3.
5
Hold “I” firmly and loosen nut “H”.
Warning: Do not loosen screw “G” more than 1 revolution as
screw is subjected to tank pressure and can burst out which can harm the
user or surrounding personnel.
Turn screw “G” clockwise to increase cut-out pressure limit or counter
clockwise to decrease cut-out pressure. (example: if the cut-out pressure
on the tank gauge reads 120 psi and desired cut out is 130 psi turn screw
“G” clockwise).
Drain air from tanks through drain valves until pump begins to charge
tanks.
4.
5.
6.
Checking Safety Relief Valve Operation
Close drain valves.
Monitor cut-out pressure to verify the new setting.
Once setting is complete, hold screw “G” firmly and tighten nut “H.”
Warning: Aftercooler, pump head, and surrounding parts are very hot; do not
touch. (see Hot Surfaces)
Pilot Valve Pressure Differential Adjustment
Note: Unit can remain running while performing this adjustment.
1.
2.
Warning: Aftercooler, pump head, and surrounding parts are very hot; do not
touch. (see Hot Surfaces)
3.
4.
Checking Air Filter Element
Warning - Moving Parts: Keep your hair, clothing and gloves away from
moving parts. Loose clothing, jewelry, or long hair can be caught in moving parts.
Air vents may cover moving parts and should be avoided as well.
1.
2.
3.
Warning: Aftercooler, pump head, and surrounding
parts are very hot; do not touch. (see Hot Surfaces)
1.
2.
3.
4.
5.
6.
Warning: Aftercooler, pump head, and surrounding parts are very hot; do not
touch. (see Hot Surfaces)
1.
2.
3.
Hold “I” firmly and loosen nut “J.”
Warning: Do not loosen barrel “I” more than 1 revolution as barrel
is subjected to tank pressure and can burst out which can harm the user
or surrounding personnel.
Turn barrel “I” clockwise to increase differential or counter clockwise to
decrease differential. (for example: if pressure differential is 100 - 130 psi
and 100 - 120 psi is desired, turn “I” counter clockwise) .
Note: Too narrow of a differential can cause chatter of the pilot valve.
Increase differential to eliminate chatter.
After desired differential is achieved, hold barrel “I” and tighten nut “J.”
Checking Compressor Pump Oil Level
Ensure unit is off.
Ensure tanks are empty by looking at tank pressure gauge. Drain tanks if
necessary.
Grasp wire ring on safety valve.
Pull and release ring a few times to ensure plunger moves in and out.
4.
5.
6.
7.
8.
Ensure unit is off.
Allow unit to cool.
Unscrew filter top from filter base by turning counter clockwise about 5
degrees.
Separate filter top from base.
Remove element from filter base.
If element needs cleaning, blow out with air. Replace element if unsure.
Place element back in filter base.
Reconnect filter top to filter base and while pushing in, rotate top
clockwise 5 degrees.
Starting Unit
N
Follow the pre-start and start-up procedures in the operating procedure section.
Turning Unit Off
Follow the shut-down procedure in the operating procedures section.
Ensure unit is off.
Locate unit onto a flat horizontal surface.
Remove dipstick (N) from crankcase (if
equipped).
Look for visual signs of contaminants
(water, dirt, etc.) Change pump oil if
contaminants are present.
Oil should not exceed top line on side of
crankcase, the top line on the dipstick or
the center of the sight glass. If necessary
fill with a quality synthetic oil.
Replace dipstick if removed.
Adjusting Regulator
1.
2.
3.
6
Pull regulator knob (N) out.
Turn knob clockwise to increase regulated pressure and counter clockwise
to decrease regulated pressure.
When desired pressure is shown on the regulated pressure gauge push
knob in to lock.
Installing Hoses
5.
Warning: Firmly grasp hose in hand when installing or disconnecting to
prevent hose whip.
6.
7.
O
8.
1.
2.
3.
4.
5.
6.
7.
Ensure regulated pressure gage reads 0 PSI.
Grasp hose in hand at coupler location.
Pull back collar on female quick connect coupler (O) located on
compressor.
Push male connector into female connector.
Release female connector
Grasp hose and pull to ensure couplers are seated.
Adjust regulator to desired pressure.
Grasp black lever on other drain valve and rotate to approximately the
same position as the first. (For twin tank units)
When tank pressure gauge reads 10 psi, rotate valve(s) to the fully open
position.
Move compressor into an inclined position so drain valve(s) are at the
lowest point (this will assist in removing moisture, dirt, etc. from tanks).
Close drain valve(s) when finished.
Preparation For Use
Initial Set-Up
Read safety instructions before setting-up air compressor.
Caution: Do not operate without lubricant or with inadequate lubricant. J-Air is
not responsible for compressor failure caused by inadequate lubrication.
Compatibility
Air tools and accessories that are run off the compressor must be compatible with
petroleum based products. If you suspect that a material is not compatible with
petroleum products, an air line filter for removal of moisture and oil vapor in
compressed air is required.
Disconnecting Hoses
Warning: Firmly grasp hose in hand when installing or disconnecting to
prevent hose whip.
Note: Always use an air line filter to remove moisture and oil vapor when spraying
paint.
1.
2.
3.
4.
5.
Ensure regulated pressure gage reads 0 PSI.
Grasp hose in hand at coupler location.
Pull back collar on female quick connect coupler located on compressor.
Pull male connector out of female connector.
Release female connector.
Location
Caution: In order to avoid damaging the air compressor, do not allow the unit to
be tilted more than 10° when operating.
Place air compressor at least 3 feet away from obstacles that may prevent proper
ventilation. Keep unit away from areas that have dirt, vapor and volatile fumes in
the atmosphere which may clog and gum up the intake filter and valves, causing
inefficient operation.
Draining Tanks
Warning: Tanks contain high pressure air. Keep outlet of drain away from
face and other body parts. Use safety glasses when draining as debris can be kicked
up into face. Use ear protection as air flow noise is loud when draining.
Humid Areas
In frequently humid areas, moisture may form in the bare pump and produce
sludge in the lubricant, causing running parts to wear out prematurely. Excessive
moisture is especially likely to occur if the unit is located in an unheated area that is
subject to large temperature changes. Two signs of excessive humidity are external
condensation on the bare pump when it cools down and a “milky” appearance in
compressor lubricant. You may be able to prevent moisture from forming in the
bare pump by increasing ventilation or operating for longer intervals.
Note: All compressed air systems generate condensate that accumulates in any
drain point (e.g., tanks, filter, aftercoolers, dryers). This condensate contains
lubricating oil and/or substances which may be regulated and must be disposed of
in accordance with local, state, and federal laws and regulations.
1.
2.
3.
4.
Ensure ON/OFF switch is in the OFF position.
Place a suitable container under the drains to catch discharge.
Grasp black lever on one drain valve.
Slowly rotate lever so as to gradually bleed air from tank.
7
Electrical
Condensate Discharge Piping
Refer to the safety instructions before using unit. Observe extension cord safety
instruction if necessary. Always shut off the air compressor switch before removing
the plug from the receptacle.
If installing a condensate discharge line, the piping must be at least one size larger
than the connection, as short and direct as possible, secured tightly and routed to a
suitable drain point. Condensate must be disposed of in accordance with local, state
and federal laws and regulations.
Noise Considerations
Consult local officials for information regarding acceptable noise levels in your
area. To reduce excessive noise, use vibration mounts or silencers, relocate the unit
or construct total enclosures or baffle walls. Contact your local service center or
call J-Air at 814-532-4149 for assistance.
Note: All compressed air systems generate condensate that accumulates in any
drain point (e.g. tanks, filter, aftercoolers, dryers). This condensate contains
lubricating oil and/or substances which may be regulated and must be disposed of
in accordance with local, state, and federal laws and regulations.
Transporting
Operating Procedures
Pre-Start Checklist
Warning: Unit weighs more than 160 lbs. Do not move or lift without
assistance.
1.
2.
3.
4.
5.
6.
7.
8.
When transporting the compressor in a vehicle, trailer, etc. ensure that the tanks are
drained and the unit is secured and placed on a flat horizontal surface. Use care
when driving so to avoid tipping the unit over in the vehicle. Damage can occur to
the unit or surrounding items if unit is tipped. Use a ramp if loading or unloading
the unit from a height of more than 12".
Always store compressor in a horizontal position, on all four rubber mounts.
Moving
When moving the unit into a position for use, grasp handle grips at rear of
compressor, and lift compressor high enough so unit can be rolled on the front
tire. When location is reached slowly lower rear of compressor to ground.
Ensure the ON/OFF lever switch is in the OFF position.
Ensure tank(s) is/are drained so that moisture, dirt, etc. can be eliminated.
Ensure tank pressure gauge reads 0 psi.
Ensure safety and drain valve(s) is/are functioning properly.
Ensure the drain valve(s) is/are closed.
Check oil level in pump.
Visually inspect drive belt. Replace belt if frayed, cracked, or worn.
Ensure all guards, covers, and labels are in place, legible (for labels) and
securely mounted. Do not use compressor until all items have been
verified.
Start-Up
1.
2.
Warning: Ensure proper footing and use caution when rolling
compressor so that unit does not tip or cause loss of balance.
3.
Air Inlet Filter
Caution: Do not operate without air inlet filter.
4.
5.
6.
General Requirements
The piping, fittings, receiver tank, etc. must be certified safe for at least the
maximum working pressure of the unit. Use hard welded or threaded steel or
copper pipes, cast iron fittings and hoses that are certified safe for the unit’s
discharge pressure and temperature. Use pipe thread sealant on all threads, and
tighten joints thoroughly to prevent air leaks. Do not use PVC plastic.
7.
8
Ensure the ON/OFF lever is in the OFF position.
Pull out and turn regulator knob counterclockwise until fully closed. Push
in to lock. Regulated pressure gage should read 0 psi.
Plug cord into a grounded wall outlet.
Warning: Make sure that the correct cord plug end is properly
connected to the compressor cordset before operating in 115- or 230-volt
mode.
Note: For dual control units, ensure the pilot valve is adjusted to the
desired setting (see the Dual Control section in the Common Procedures).
Rotate manual lock on pilot valve to an in-line position.
Turn the ON/OFF lever to the ON position.
Rotate manual lock on pilot valve to a perpendicular position so pump
will charge tanks.
Allow compressor to pump up to “cut out” pressure.
Note: For constant run operation on units: after the compressor
reaches cut-out pressure the unit will continue to run but will not charge
air. A slight air noise may be heard, which is the unloading of the air
compressor. For Stop/Start units: after the compressor reaches cut-out
8.
9.
Maintenance Chart
pressure the unit will turn off and a slight air noise will be heard, which is
the unloading of the head through the pressure switch. If unit does not
stop, refer to the Dual Control section in the Common Procedures
section.
Note: If any unusual noise or vibration is noticed, stop the compressor
and refer to the troubleshooting section.
Attach hose and accessory.
Adjust regulator to desired setting.
Procedure
Check pump oil level
Oil leak inspection
Drain condensation in air tank(s)
Check for unusual noise/vibration
Check for air leaks*
Inspect belt
Inspect air filter
Clean exterior of compressor
Check safety relief valve
Check belt adjustment
Change pump oil **
Shut-Down
Note: Never stop the air compressor by unplugging it from the power source. This
could result in damage to the unit.
1. Move the ON/OFF lever to the OFF position.
Note: If finished using compressor, follow steps 2 - 7 below.
2. Unplug cord from wall outlet.
3. Turn regulator knob counterclockwise until fully closed. Ensure regulated
pressure gauge reads 0 PSI.
4. Remove hose and accessory.
5. Drain the air tank(s).
6. Allow the compressor to cool down.
7. Wipe air compressor clean and store in a safe, non freezing area.
Day
X
X
X
X
X
X
Week
1 Year or
Month 200 Hrs.
X
X
X
X
X
* To check for air leaks apply a solution of soapy water around joints. While
compressor is pumping to pressure and after pressure cuts out look for air bubbles.
** The pump oil must be changed after the first 20 hours of operation. Thereafter,
when using a quality synthetic oil, change oil every 200 hours of operation or once
a year, whichever comes first. In harsh environments, maintenance must be
performed on a more accelerated schedule.
Compressor Pump Oil Change
Maintenance
Note: Pump oil contains substances that are regulated and must be disposed of in
accordance with local, state and federal laws and regulations.
Warning: Aftercooler, pump head, and surrounding parts are very hot; do not
touch. (see the Hot Surfaces identified on page 2)
The following procedures must be followed when maintenance or service is
performed on the air compressor.
1.
2.
3.
4.
Turn off air compressor.
Disconnect cord from electrical outlet.
Drain tank(s).
Allow air compressor to cool down before starting service.
Note: All compressed air systems contain maintenance parts (e.g.
lubricating oil, filters, separators) that are periodically replaced. These used
parts may contain substances that are regulated and must be disposed of
in accordance with local, state, and federal laws and regulations.
Note: Take note of the positions and locations of parts during disassembly to
make reassembly easier.
1.
2.
3.
4.
5.
6.
Note: Any service operations not included in this section should be performed by
authorized service personnel.
7.
8.
9.
9
Ensure unit is off.
Allow the unit to cool.
Locate a suitable container under
drain plug (P).
Remove dipstick (N)
Remove the oil drain plug.
Allow ample time for all oil to drain
N
out. (Tilting the compressor towards
the drain plug will assist in draining.)
Reinstall the oil drain plug.
Fill pump with a quality synthetic
P
compressor oil. Oil should not exceed
top raised line on side of crankcase ,
the top line on the dipstick or the center of the sight glass.
Install dipstick.
Checking Belt Tension
Repairs
To assure product SAFETY and RELIABILITY, repairs, maintenance and
adjustment should be performed by authorized service centers or other qualified
service organizations, always using compatible replacement parts.
Warning: Aftercooler, pump head, and surrounding parts are very hot; do not
touch (see the Hot Surfaces identified on page 2).
1. Ensure unit is off and unplugged from wall.
2. Allow unit to cool down so pump can be touched.
3. Using a long screwdriver or similar device, push on the belt in the middle
of the span with approximately 8 lbs. of force and notice the amount of
deflection. Belt should not more than 1/2”; if so, see Adjusting Belt
Tension section.
Full One Year Warranty
J-Air compressors are warranted for one year from date of purchase. We will repair,
without charge, any defects due to faulty materials or workmanship. For warranty
repair information, call 814-532-4149. This warranty does not apply to
accessories or damage caused where repairs have been made or attempted by
others. This warranty gives you specific legal rights and you may have other rights
which vary in certain states or provinces.
Adjusting Belt Tension
Warning: Pump and surrounding components are hot.
1. Loosen four screws on bottom of belt guard.
2. Loosen four pump mounting bolts.
3. Adjust belt tension using the belt tensioning bold located on the end of
the deck.
Warning: Do not over-tighten. Too much pressure on the belt will
cause premature failure to the belt, pump and/or motor.
4. Check belt tension again.
5. Once acceptable tension is reached, retighten pump bolts.
Warning: Make certain belt alignment is correct, and pump base is
parallel with deck. This assures proper flywheel and motor pulley
alignment.
6. Retighten belt guard screws.
Accessories
Recommended accessories for use with your tool are available for purchase from
your local dealer or authorized service center. If you need assistance in locating any
accessory for your tool, contact: J-Air Compressors, PO Box 1286
Johnstown, PA 15907 or call 814-532-4149.
Caution: The use of any other accessory not recommended for use with this tool
could be hazardous.
Service Information
Please have the following information available for all service calls:
Model Number _____________
Serial Number _______________
Date and Place of Purchase _____________________________
10
TROUBLESHOOTING GUIDE
This section provides a list of the more frequently encountered malfunctions, their causes and corrective actions. The operator or
maintenance personnel can perform some corrective actions, and others may require the assistance of a qualified J-Air technician or
your dealer.
Problem Code
Compressor does not start or restart .................................................................................………...........16,17,18,19,20,36
Unit does not or is slow to come up to speed ......................................................................……..........3,8,11,12,14,15,20,21,22,24,25,31
Air compressor not making enough air....................................................................................…….........1,3,7,8,9,10,11,21,24,25,28,29
Insufficient pressure at air tool or accessory .....................................................................……..............1,3,7,8,9,10,11,21,24,25,27,28,29
High oil consumption.............................................................................................................……….........2,6,9,10,11,12,15,30,32
Unit runs excessively hot .....................................................................................................………...........1,2,4,5,10,11,12,13,15,19,30
Excessive starting and stopping ...........................................................................................……….........7,20,21,24,25,29
Excessive noise during operation ........................................................................................……….........2,3,4,5,8,9,10,11,12,15,25,29,30,31
Moisture in discharge air..........................................................................................................……….......34,35
Moisture in crankcase or "milky" appearance in petroleum lubricant or rusting in cylinders ..........6,7,9,10,15,25,26,33,35
Oil in discharge air (oil pumping) ..............................................................................................…….......2,6,8,9,10,11,15,31,32
Oil leaking from shaft seal.........................................................................................................……….....12
Safety relief valve "pops" ........................................................................................................………......22,23
Air leaks at pump ..............................................................................................................………............24,25
Air leaks at fittings ..................................................................................................................……...........25
Air leaks from tank ...........................................................................................................……….............26
Abnormal piston ring or cylinder wear ............................................................................……..............2,4,5,6,9,10,11,13
11
Code
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Possible Cause
Clogged or dirty inlet and or discharge line filter.
Lubricant viscosity too low or too high.
Lubricant viscosity too high.
Lubricant level too low.
Detergent type lubricant being used.
Extremely light duty cycles.
Compressor check valve leaky, broken, carbonized or loose.
Carbon build up on top of piston.
Piston rings damaged or worn (broken, rough, or scratched). Excessive
end gap or side clearance. Piston rings not seated, are stuck in grooves
or end gaps not staggered.
Cylinder or piston scratched, worn, or scored.
Connecting rod, piston pin, or crankpin bearings worn or scored.
Crankshaft seal worn or crankshaft scored.
Extremely dusty atmosphere.
Ambient temperature too low.
Worn cylinder finish.
Power cord not plugged in.
Motor thermal overload switch has tripped.
18.
Fuse blown or circuit has tripped.
19.
Wrong gauge wire or length of extension cord.
20.
21.
Defective motor, motor capacitor or pressure switch.
Air compressor is not large enough for air required.
22.
23.
24.
25.
Possible defective safety/relief valve.
Excessive air tank pressure.
Defective gaskets.
Fittings not tight enough.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Defective or rusted air tank.
Pressure regulator knob not turned to high enough pressure.
Hose or hose connections are too small or long.
Possible defective valve.
Air compressor on uneven surface.
Crankcase overfilled with oil.
Plugged oil crankcase vent.
Water in oil due to condensation.
Condensation in air tank caused by high level of atmospheric humidity.
35.
36.
Unit located in damp or humid location.
Tanks have air pressure.
Possible Solution
Clean or replace.
Drain existing lubricant and refill with a quality synthetic lubricant.
Drain existing lubricant and refill with a quality synthetic lubricant.
Add lubricant to crankcase to proper level. Check for bearing damage.
Drain existing lubricant and refill with a quality synthetic lubricant.
Run unit for longer duty cycles.
Clean or replace as required. Inspect valves.
Clean piston. Repair or replace as required.
Install new rings.
Repair or replace as required.
Inspect all. Repair or replace as required.
Replace seal or crankshaft assembly.
Install more effective filtration or relocate unit.
Relocate unit to warmer environment. Ensure quality synthetic oil is in crankcase
Deglaze cylinder with 180 grit flex-hone.
Plug cord into grounded outlet.
Turn air compressor off. Wait until motor is cool, then press motor thermal overload
button firmly until click is heard (located on motor.).
Replace fuse or reset circuit breaker. Check for proper fuse; only “Fusetron” type T fuses
are acceptable. Check for low voltage conditions. Disconnect any other electrical
appliances from circuit or operate air compressor on its own branch circuit.
Check chart on page #3 for proper gauge wire and cord length. If possible, eliminate
extension cord.
Contact J-Air Customer Service at 814-532-4149.
Check the accessory air requirement. If it is higher than the CFM or pressure supply of
the air compressor, you need a larger air compressor.
Operate safety relief valve manually by pulling on test ring. If it still leaks, replace.
Adjust pilot valve. If problem still exists, replace pilot valve.
Replace and torque head bolts to 19 ft lb.
Warning: Drain air before tightening: tighten fittings where air cannot be heard escaping.
Check joint with soap solution. Do not over tighten.
Air tank must be replaced. Do not attempt to repair air tank.
Adjust pressure regulator knob to proper setting or replace defective pressure regulator.
Replace with larger hose or connectors.
Remove pump head and inspect valve plate and valve. Clear or replace valves as required.
Do not incline the air compressor more than 10° in any direction while running.
Drain oil. Refill to proper level with a quality synthetic oil.
Clean.
Drain oil. Refill to proper level with a quality synthetic oil.
Drain air tank after every use. Drain air tank more often in humid weather and use an air
line filter.
Relocate unit.
Bleed tanks fully.
12
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