Troubleshooting guide | DeVillbiss Air Power Company C102D

OWNERS MANUAL FOR
PERMANENTLY LUBRICATED
AIR COMPRESSOR
MODEL NO. 102D-1
(For Home Use Only)
SPECIFICATION CHART
Model No.
Horsepower
SCFM @ 40 psig
SCFM @ 90 psig
Displacement CFM
Bore
Stroke
Voltage-Single Phase
Minimum Branch Circuit Requirement
*Fuse Type
Tank Size
102D-1
3/4
3.0
2.2
4.0
1 3/4"
1 1/4"
110-120
15 AMPS
Quick Acting
2 Gallon
C102D-1
--3.0
2.2
4.0
1 3/4"
1 1/4"
110-120
15 AMPS
Quick Acting
2 Gallon
*A circuit breaker is preferred. Use only a fuse or circuit breaker that is the same rating
as the branch circuit the air compressor is operated on. If the air compressor is
connected to a circuit protected by fuses, use quick acting fuses.
This unit is a continuous run unit. It does not start and stop automatically.
NOTE:
IMPORTANT:
For identification of Repair Parts,
see separate Parts List Manual.
Read and Retain the Safety
Guidelines and All Instructions
Carefully Before Operating.
WARRANTY:
For Warranty Information
see page 3 of this manual.
DeVilbiss Air Power Company, 213 Industrial Dr., Jackson, TN 38301-9615
MGP-102D-2 2/1/94
TABLE OF CONTENTS
Page
WARRANTY ........................................................
3
SAFETY GUIDELINES .......................................... 4
Page
Location of Air Compressor ...........................
Extension Cords ...........................................
Grounding Instructions ..................................
Air Hose ........................................................
6
6
6
7
OPERATING PROCEDURES ...............................
7
TROUBLESHOOTING GUIDE ..............................
8
WARNING CHART ............................................... 4-5
GLOSSARY .........................................................
5
UNPACKING INSTRUCTIONS ..............................
5
STORAGE ...........................................................
5
DUTY CYCLE ......................................................
5
DESCRIPTION OF OPERATION ...........................
6
AIR COMPRESSOR DIAGRAM
AND PARTS LIST ................................................ 9-10
COMPRESSOR PUMP DIAGRAM
AND PARTS LIST ............................................. 11-12
HOW TO ORDER REPAIR PARTS .....................
INSTALLATION AND BREAK-IN
PROCEDURES ....................................................
13
6
In the unlikely event you should have a problem with this product or if you are
missing any parts, it is not necessary to return it to the store where you purchased
it. Simply call our toll free number and talk with our Service Representative.
OUR OFFICE HOURS ARE FROM
8 a.m. to 4:30 p.m. (CST)
MONDAY THROUGH FRIDAY
CALL TOLL FREE 1-800-888-2468, Ext. 2
2
LIMITED WARRANTY
ONE YEAR FROM DATE OF PURCHASE
All merchandise manufactured by DeVilbiss Air Power Company 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 and service parts.
DeVilbiss Air Power will repair or replace, at DeVilbiss's option, products or components 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 at
the service center location, and depending on the availability of replacement parts.
All decisions of DeVilbiss Air Power Company 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):
o
o
Retain original sales receipts as proof of purchase for warranty work.
Use reasonable care in the operation and maintenance of the product as described in the Owners
Manual(s).
o Deliver or ship the product to the nearest DeVilbiss Air Power Authorized Warranty Service
Center. Freight
costs, if any, must be paid by the purchaser.
o 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.
o If the purchaser does not receive satisfactory results from the Authorized Warranty Service
Center, the
purchaser should contact DeVilbiss Air Power Company.
THIS WARRANTY DOES NOT COVER:
or
o
Merchandise sold as, reconditioned, floor models and/or display models sold "as is", any damaged
incomplete equipment sold "as is".
o Merchandise used as "rental" equipment.
o Merchandise that has become inoperative because of ordinary wear, misuse, 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.
o An air compressor that pumps air more than 50% during a one hour period is considered
misuse because
the air compressor is undersized for the required air
demand. Maximum compressor pumping time per hour is
30 minutes.
o Merchandise sold by DeVilbiss Air Power which has been manufactured by and identified as the
product of
another company. The product manufacturer's warranty will apply.
o Repair and transportation costs of merchandise determined not to be defective.
o Cost associated with assembly, required oil, adjustments or other installation and start-up cost.
o ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY
RESULT
FROM ANY DEFECT, FAILURE OR MALFUNCTION OF THE
PRODUCT. Some states do not allow the
exclusion or limitation of incidental
*Air Tools: O-Rings
and driver
are considered
ordinary
parts, therefore,
they are warranted for a period of 45 days
or consequential
damages,
soblades
the above
limitation
or wear
exclusion
may not
ap-from
theply
datetoofyou.
purchase.
o IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A
Form: SP-100-C
PARTICULAR
6/4/93
213 Industrial Drive • Jackson, TN 38301-9615 • Telephone: 1-800-888-2468 , Ext. 2 • FAX: 1-800-888PURPOSE, ARE LIMITED TO ONE YEAR FROM THE
9036 DATE OF ORIGINAL PURCHASE. Some
3
states do not
allow limitations on how long an implied warranty lasts, so the above limitations may not apply to
SAFETY GUIDELINES
This manual contains information that is important for you to know and understand. This information relates to protecting
YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the
following symbols. Please read the manual and pay attention to these sections.
URGENT SAFETY INFORMATION - A
HAZARD THAT WILL CAUSE
SERIOUS INJURY OR LOSS OF LIFE.
IMPORTANT SAFETY INFORMATION A HAZARD THAT MIGHT CAUSE
SERIOUS INJURY OR LOSS OF LIFE.
Information for preventing damage to equipment.
NOTE
Information that you should pay special
attention to.
HAZARDS CAN OCCUR IF EQUIPMENT IS NOT USED PROPERLY.
PLEASE READ THE FOLLOWING CHART.
WHAT TO
LOOK FOR
Hot Parts
Flammable
Vapors
WHAT COULD HAPPEN
HOW TO PREVENT IT
When operated continuously, the air hose gets hot,
especially near the compressor. If you maintain contact by grasping you may suffer minor burns or discomfort.
Never touch the air compressor head during or immediately after operation.
On tank mounted units, the plumbing between the
pump and tank gets hot.
On tank mounted units, avoid prolonged contact with
the pump to tank plumbing.
It is normal for the motor and pressure switch to spark.
A spark can ignite flammable vapors from gasoline or
solvents, causing a fire or explosion.
The air compressor must only be used in well ventilated
areas, free of gasoline or solvent vapors.
Do not operate the compressor while you are carrying
it, or in the spray area.
Compressed
Air
Compressed air can propel dust, dirt or loose particles
it comes in contact with. These propelled particles may
cause serious injury or damage.
Never point any nozzle or sprayer toward a person or
any part of the body.
Always wear safety goggles or glasses when using the
air compressor.
Always turn the air compressor off before attaching or
removing accessories.
Too much air pressure applied to air tools or accesso- Check the manufacturer’s pressure rating for air tools
ries can cause damage or risk of bursting.
and accessories. Regulator outlet pressure must never
exceed the maximum pressure rating.
4
WHAT TO
LOOK FOR
Electricity
HOW TO PREVENT IT
WHAT COULD HAPPEN
Your air compressor is powered by electricity. Like any
other electrically powered device, if it is not used
properly it may cause electrical shock.
Always unplug the air compressor prior to maintenance
or repair.
Never use the air compressor in the rain.
Always plug the cord into an electrical outlet with the
specified voltage and adequate fuse protection.
Toxic Vapors
It is normal for compressed air to contain toxic or
irritating vapors. Such vapors are harmful if inhaled.
Never directly inhale the compressed air produced by
this unit.
Certain materials you are spraying (like paint, weed
killer, sand or insecticide) can be harmful if you inhale
them.
Read labels and safety data for all materials you spray.
Follow all safety precautions.
Read and follow the safety instructions provided on the
label or safety data sheet for the material you are
spraying. Use a respirator mask if there is a chance of
inhaling anything you are spraying. Read all instructions . . . be sure that the respirator mask is suitable for
your application.
Unsuitable
Solvents
The solvents 1,1,1 - Trichloroethane and Methylene
Chloride can chemically react with aluminum used in
paint spray guns, paint pumps, etc., and cause an
explosion. These solvents can also react with galvanized components and cause corrosion and weakening of parts. This does not affect your air compressor
- but it may affect the equipment being used.
Read the label or data sheet supplied with the material
you intend to spray. If it contains the solvents listed do
not use accessories that contain aluminum or galvanized parts. You must either change the material you
intend to spray, or use only stainless steel spray equipment.
GLOSSARY
SCFM or CFM: Standard Cubic Feet per Minute; a unit of
measurement of air delivery.
PSIG or PSI: Pounds per square inch gauge.
U.L. Listed: Products with the U.L. mark are listed by
Underwiters Laboratories, Inc. (U.L.). Samples of these
products have been evaluated by U.L. and meet the
applicable U.L. Standards of Safety.
UNPACKING INSTRUCTIONS
Grasp the handle and lift the air compressor out of the carton. Remove the styrofoam and/or cardboard and
discard.
STORAGE
When you have finished using the air compressor:
1. Set the "ON/OFF" switch to "OFF" and unplug the 3. Protect the electrical cord and air hose from damage
cord.
by winding them loosely around the air compressor.
2. Relieve all pressure from the air compressor head and
4. Store the air compressor in a clean and dry location.
air hose by setting the adjustable pressure valve to 10
P.S.I.
DUTY CYCLE
All DeVilbiss Air Power manufactured air compressors should be operated on not more than a 50% duty cycle. This
means an air compressor that pumps more than 50% of one hour, is considered misuse, because the air compressor
is undersized for the required air demand. Maximum compressor pumping time per hour is 30 minutes.
5
DESCRIPTION OF OPERATION
Air Compressor Pump: To compress air, the piston
moves up and down in the cylinder. On the downstroke,
air is drawn in through the air intake muffler (valves). The
exhaust valve remains closed. On the upstroke of the
piston, air is compressed. The intake valves close and
compressed air is forced out through the exhaust valve
and then through the air hose.
Adjustable Pressure Valve: The pressure valve controls
the amount of pressure going from the air compressor to
the accessory. The pressure adjusting valve can be used
to set approximate pressure between 10 and 125 P.S.I.
(125 P.S.I. is the highest pressure this compressor will
deliver). It is normal for the adjustable pressure valve to
release air during operation.
Accumulator Tank: Your accumulator tank is equipped
with a relief (pop-off) valve to prevent an over pressure
condition in the tank. This 2 gallon tank is not designed to
store air, but rather to provide the additional volume of
compressed air necessary to operate a wide variety of air
tools. When starting your compressor, attach the tool to
the hose, set the pressure adjusting valve at the required
pressure, wait a few moments until the tank fills with air.
You will know the tank is filled when you hear air bleeding
through the pressure adjusting valve. Depending on the
type and size of tool being used, you will occasionally
need to wait for the tank to refill before continuing. When
you are finsihed or changing tools, turn the compressor
switch off and set the pressure adjusting valve to 10 PSI
and wait for the tank to discharge completely.
ALWAYS SET THE PRESSURE VALVE AT OR
BELOW THE REQUIRED PRESSURE FOR THE
ACCESSORY BEING USED BEFORE STARTING YOUR COMPRESSOR. FOR INFLATION
OR OTHER USES REQUIRING ACCURATE
PRESSURE, USE A PRESSURE GAUGE.
INSTALLATION AND BREAK-IN PROCEDURES
Location of the Air Compressor
Your compressor comes to you completely assembled
and ready for use. Operate the air compressor in a dry,
clean, cool and well ventilated area. The air compressor
pump and case are designed to allow for proper cooling.
Clean or blow off dust or dirt that collects on the air
compressor. A clean air compressor runs cooler and
provides longer service. The ventilation openings on your
air compressor are necessary to maintain proper operating temperature. Do not place rags or other containers on
or near these openings.
Extension Cords
Use extra air hose instead of an extension cord to avoid
voltage drop and power loss to the motor.
If an extension cord must be used, be sure it is:
• a 3-wire extension cord that has a 3-blade grounding
plug, and a 3-slot receptacle that will accept the plug on
the compressor
• in good condition
• no longer than 50 feet
• 14 gauge (AWG) or larger. (Wire size increases as gauge
number decreases.) 12 AWG, 10 AWG and 8 AWG may
also be used. DO NOT USE 16 OR 18 AWG.
6
GROUNDING INSTRUCTIONS
RISK OF ELECTRICAL SHOCK! In the event of a
short circuit, grounding reduces the risk of shock by
providing an escape wire for the electric current.
This air compressor must be properly grounded.
The air compressor is equipped with a cord having a
grounding wire with an appropriate grounding plug.
The plug must be used with an outlet that has been
installed and grounded in accordance with all local
codes and ordinances. The outlet must have the same
configuration as the plug. See illustration. DO NOT
USE AN ADAPTER.
Inspect the plug and cord before each use. Do not use if
there are signs of damage.
IMPROPER GROUNDING CAN RESULT IN ELECTRICAL SHOCK.
INSTALLATION AND BREAK-IN PROCEDURES
Do not modify the plug that has been provided. If it
does not fit the available outlet, the correct outlet
should be installed by a qualified electrician.
If repairing or replacing cord or plug, the grounding
wire must be kept separate from the current-carrying
wires. Never connect the grounding wire to a flat blade
plug terminal. The grounding wire has insulation with
an outer surface that is green - with or without yellow
stripes.
If these grounding instructions are not completely
understood, or if in doubt as to whether the compressor is properly grounded, have the installation checked
by a qualified electrician.
Air Hose
The air hose attached to your comporessor has an integral
pressure adjusting valve at the working end of the hose.
Should service or replacement be required, make sure that
the pressure adjusting valve is present in the air hose line.
DO NOT REPLACE THE HOSE WITH STANDARD HOSE
THAT IS NOT EQUIPPED WITH THE PRESSURE ADJUSTING VALVE.
Do not allow hose to become kinked or pinched
at any time. This is important to avoid damage
to your compressor and to maintain pressure
adjusting valve control.
120 Volts, 15 Amps
OPERATING PROCEDURES
1. Before plugging in the air compressor, set the adjustable pressure valve to "10" PSI. Make sure the "ON/
OFF" switch is in the "OFF" position.
2. Connect the air tool or accessory to the air hose.
Tighten securely.
3. Plug the power cord into the grounded outlet.
4. Start the compressor by setting the "ON/OFF" switch
to the "ON" position.
TOO MUCH AIR PRESSURE COULD CAUSE AN
AIR TOOL OR VEHICLE TIRE TO RUPTURE OR
EXPLODE. CAREFULLY FOLLOW STEPS 5 AND
6 EACH TIME YOU USE YOUR COMPRESSOR.
5. Check the manufacturer's maximum pressure rating
for the air tool, accessory or vehicle tire being used.
The air compressor outlet pressure must never exceed
the maximum pressure rating.
6. Slowly increase the pressure setting of the adjustable
pressure valve. You should be able to hear and feel air
pressure being relieved by the adjustable pressure
valve. If pressure is not being relieved, turn the air
compressor off immediately. The pressure valve must
be replaced.
Compressed air from the outfit may contain
water condensation. Do not spray unfiltered air
at an item that could be damaged by moisture.
Some air operated tools or devices may require
filtered air. Read the instructions for the air tool
or device.
7
TROUBLESHOOTING GUIDE
VOLTAGE SOURCES, MOVING PARTS OR COMPRESSED AIR SOURCES ARE
EXPOSED WHEN REPAIRING THE COMPRESSOR. PERSONAL INJURY CAN
OCCUR. UNPLUG THE COMPRESSOR BEFORE ATTEMPTING ANY REPAIRS.
PROBLEM
CAUSE
SOLUTION
Air Leaks
Hose fitting loose.
Tighten fitting.
Compressor is not delivering
enough air.
Prolonged excessive use of air.
Decrease the amount of air usage. Your compressor is not large enough for the air requirement.
Hole in hose.
Replace the hose.
Air leaks.
Tighten fittings.
Fuse blown, circuit breaker tripped.
1. Check fuse box for blown fuse and replace as
necesssary. Reset circuit breaker. Do not
use a fuse or circuit breaker with higher rating
than that specified for your particular branch
circuit.
Motor will not run.
2. Check for proper fuse. You should be using
a Quick Acting fuse.
3. Check for low voltage problem.
4. Check the extension cord.
5. Disconnect the other electrical appliances
from circuit or operate the compressor on its
own branch circuit.
High discharge pressure.
Cannot be adjusted lower.
Extension cord is wrong length or
gauge.
Check the extension cord.
Loose electrical connections.
Check wiring connection inside terminal box
Faulty motor.
Have checked at a local Service Center.
Adjustable pressure valve not functioning.
RISK OF BURSTING. DO NOT OPERATE THE COMPRESSOR IF THIS PROBLEM EXISTS. ADJUSTABLE PRESSURE
VALVE MUST BE REPLACED.
8
Air Compressor Diagram
7
Slide #19 over #7 as shown. Make sure that no part of #7 tube
touches #21 or #14 shroud when assembled.
9
Parts List
KEY
NO.
/
*
*
*
+
/
+
*
PART NUMBER
----CAC-1196
--------CAC-4323
----CAC-1289
------------CAC-4111
CAC-1342
----DAC-163
DAC-168
SSS-16
------------CAC-1285
CAC-4322-1
DAC-162
DAC-167
-----
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
* 16
> 17
> 18
19
20
21
/ 22
*
/
>
+
10
KK-4949
KK-4929
KK-4980
KK-4926
DESCRIPTION
Screw #10-24 x 7/8 LG hex head thd. forming (4 required)
Cylinder Head
Tube Seal
Head Gasket
Valve Plate Assembly
"O" Ring
Outlet Tube
Rod Assembly
Screw 3/8-16 x 1/25 LG hex socket flat head (torque to 350 in/lb)
Cylinder Sleeve
Endbell Assembly
Timing Belt
Pump Isolator (5 required)
Shroud (right) for 102D-1
Shroud (right) for C102D-1
Switch
Tank Isolator (4 required)
Motor Baffle (right)
Motor Baffle (left)
Isolator (tube)
Cord Assembly
Shroud (left) for 102D-1
Shroud (left) for C102D-1
Screws (5 used)
Isolator Kit includes Items 3, 4, 6, 13, 16, 34, 35, 27
Fastener Kit includes items 1, 9, 22, 25.
Baffle Kit includes items 17, 18.
Connecting Rod Kit includs items 8, 10.
Compressor Pump Diagram
11
Parts List
KEY
NO.
23
24
25
26
* 27
28
29
30
31
33
* 34
* 35
*
12
PART NUMBER
DESCRIPTION
CAC-1206
CAC-4324
CAC-4076
----SSP-6102
----SSP-3305-NI
TIA-4150
H-2105
SS-1286
SS-2707
---------
Clamp(2 used)
Pressure Valve Assembly for 102D-1
Pressure Valve Assembly for C102D-1
Ground Screw
Male Connector
Screw (tank retention) (as required)
Pipe Cross
Safety Valve
Hose Connection
Nipple
Drain Cock
Screw, self tapping
Recess Bumper
SSH-8
H-2099
NOT ILLUSTRATED
Air Chuck
Adapter
KK-4949
Isolator Kit includes items 3, 4, 6, 13, 16, 34, 35, 27
Service Notes
13
Service Notes
14
Service Notes
15
OWNERS MANUAL FOR
PERMANENTLY
LUBRICATED
AIR COMPRESSOR
MODEL NOS.
102D-1
(For Home Use Only)
Attach Sales Receipt Here.
Retain Original Sales Receipt as
Proof of Purchase for Warranty
Repair Work.
WARRANTY
This product is covered by the
DeVilbiss one year limited
warranty (SP-100-C). The
warranty can be found in the
General Manual or is available
upon request.
An "Authorized Warranty Service Center Directory" is included with your
unit.
When ordering repair parts from your local Authorized Service Center,
always give the following information:
•
Model number of your compressor
• Part number and description of the item
you wish to purchase
If you have any questions or need the location of the nearest Authorized
Service Center call our Customer Service Hotline (Toll Free) 1-800-8882468, Ext 2, Monday thru Friday 8:00 a.m. to 4:30 p.m. (CST) and talk with
our Trained Customer Service Representatives.
The Model number can be
found on the maintenance
label on the side of the tank.
The Date Code number can
be found on the foil label on
the air tank.
Model
No.__________________
Date
Code
No.________________
The
Manufactures
Number (ASME code
compressors only) is
located on the metal data
plate which is welded on
to the backside of the air
tank.
MFG
No.__________________
DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615
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