Eaton Compressor 5HP Inline Piston Air Compressor Operating instructions

Polar Air Electric Operated, Piston Compressors

1

Operating Instructions

ELECTRIC OPERATED,

PISTON COMPRESSORS

Polar Air designs and manufactures products for safe operation. However, operators and maintenance persons are responsible for maintaining safety. All safety precautions are included to provide a guideline for minimizing the possibility of accidents and property damage while equipment is in operation. Keep these instructions for reference.

2


Model Specification Charts . . . . . . . . . . . . .3-4

Description . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Information . . . . . . . . . . . . . . . . . . . 5

Tag Definitions . . . . . . . . . . . . . . . . . . . . 5

Basic Guidelines . . . . . . . . . . . . . . . . . . 5

Breathable Air . . . . . . . . . . . . . . . . . . . . 6

Pressurized Components . . . . . . . . . . . . . . 6

Personal Protective Equipment . . . . . . . . . . 6

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6

Forklift Safety . . . . . . . . . . . . . . . . . . . . . 7

Lifting Safety . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8

Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Piping Safety . . . . . . . . . . . . . . . . . . . . . 8

Piping / Tank Installation . . . . . . . . . . . . . 9

Electronic Auto Drain (if equipped) . . . . . . 10

Electrical Safety . . . . . . . . . . . . . . . . . . . 11

Wiring Installation . . . . . . . . . . . . . . . . . . 12

Contents

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety Rules . . . . . . . . . . . . . . . . . . . . . . 13

Start Up . . . . . . . . . . . . . . . . . . . . . . . 14

Continuous Run Feature . . . . . . . . . . 15

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 15

Safety Steps . . . . . . . . . . . . . . . . . . . . . . 15

Belt Adjustment . . . . . . . . . . . . . . . . . . 16

Changing Oil . . . . . . . . . . . . . . . . . . . . . 17

Safety Valve . . . . . . . . . . . . . . . . . . . . . 17

Tank . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance Schedule . . . . . . . . . . . . . . . . 18

Troubleshooting . . . . . . . . . . . . . . . . . . . . 18

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Polar Air Electric Operated, Two-Stage, 5-10 Hp Piston Air Compressors

Model

Tank Type

Dimensions

Model

L•W•H

(inches)

Tank Type

Dimensions

L•W•H

(inches)

Tank Size

Description

SCFM @ 175 psi

Max PSI

Motor HP

Motor RPM

Voltage

Pump Model

Pump RPM

Noise DB(A)

Outlet Connection

Weight (±5 lbs.)

Shipping Weight

PP05H080I1

Horizontal

76 x 30 x 56

PP05V080I1

Vertical

34 x 24 x 72

80 Gallon

5HP

Single Phase

17.0

175

5HP

1750

208V/230V

APP2I0524T

650

73

NPT 3/4”

715

800

PP07H080V1

Horizontal

76 x 30 x 56

PP07V080V1

Vertical

34 x 24 x 72

80 Gallon

7.5HP

Single Phase

26.0

175

7.5HP

1750

208V/230V

APP4V1043T

640

73

NPT 3/4”

958

1043

PP10H120Y1

Horizontal

78 x 32 x 50

PP10V120Y1

Vertical

50 x 32 x 78

120 Gallon

10HP

Single Phase

35.0

175

10HP

1750

208V/230V

APP3Y1544T

600

76

NPT 1”

1095

1242

PP07H080V3

Horizontal

76 x 30 x 56

PP07V080V3

Vertical

34 x 24 x 72

80 Gallon

7.5HP

Three Phase

26.0

175

7.5HP

1750

208/230/460/575

APP4V1043T

640

73

NPT 3/4”

958

1043

PP10H120Y3

Horizontal

78 x 32 x 50

PP10V120Y3

Vertical

50 x 32 x 78

120 Gallon

10HP

Three Phase

35.0

175

10HP

1750

208/230/460/575

APP3Y1544T

600

76

NPT 1”

1095

1242

3


Polar Air Electric Operated, Two-Stage, 5-10 Hp Piston Air Compressors

Model

Description

SCFM @ 175 psi

Max PSI

Motor HP

Motor RPM

Voltage

Tank Size

Pump Model

Pump RPM

Noise DB(A)


Dimensions

L•W•H

(inches)

Weight (lbs.)

Shipping Weight

PP15V120Y3

15 Hp

Three Phase

52.0

175

15 Hp

1750

208/230/460/575

120 Gallon

Vertical

APP3Y2062T

640

76

NPT 1”

33 x 24 x 73

1410

1512

PP15H120Y3

15 Hp

Three Phase

52.0

175

15 Hp

1750

208/230/460/575

120 Gallon

Horizontal

APP3Y2062T

640

76

NPT 1”

79 x 32 x 62

1410

1512

PP20H120V3

20 Hp

Three Phase

68.0

175

20 Hp

1750

208/230/460/575

120 Gallon

Horizontal

APP4V2598T

640

78

NPT 1”

72 x 30 x 51

1500

1609

Description

Unit configuration and appearance varies by model.

Callouts are for general identification.

PP25H120V3

25 Hp

Three Phase

89.0

175

25 Hp

1750

208/230/460/575

120 Gallon

Horizontal

APP4V2598T

740

79

NPT 2”

72 x 30 x 51

1703

1810

4


Safety Information

This manual contains very important information to know and understand. This is provided for SAFETY and to

PREVENT EQUIPMENT PROBLEMS . To help understand this information, observe the following:

DANGER

Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

NOTICE

Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Notice indicates important information, that if not followed, may cause damage to equipment.

Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment.

Basic Guidelines

WARNING

CALIFORNIA PROPOSITION 65

This product or its power cord may contain chemicals known to the State of

California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

1. Allow only trained, authorized persons who have read and understood these operating instructions to use this compressor. Failure to follow the instructions, procedures and safety precautions in this manual can result in accidents and injuries.

2. NEVER start or operate the compressor under unsafe conditions. Tag the compressor, disconnect and lock out all power to it to prevent accidental start-up until the condition is corrected.

3. Install, use and operate the compressor only in full compliance with all pertinent OSHA regulations and all applicable Federal, State & Local codes, standards and regulations.

4. NEVER modify the compressor and/or controls in any way.

5. Keep a first aid kit in a convenient place. Seek medical assistance promptly in case of injury. Avoid infection by caring for any small cuts and burns promptly.

5


Breathable Air

1. NEVER use air from this compressor for breathable air except in full compliance with OSHA

Standards 29 CFR 1910 and any other Federal, State or Local codes or regulations.

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards on safety equipment.

DANGER

2. DO NOT use air line anti-icer systems in air lines supplying respirators or other equipment used to produce breathable air. DO NOT discharge air from these systems in unventilated or other confined

areas.

Pressurized Components

This equipment is supplied with a ASME designed pressure vessel protected by an ASME rated relief valve. Pull the ring before each use to make sure the valve is functional. Refer to figure 10. DO NOT attempt to open valve while the machine is under pressure.

Personal Protective Equipment

Be sure all operators and others around the compressor and its controls comply with all applicable OSHA, Federal,

State and Local regulations, codes and standards relating to personal protective equipment. This includes respiratory protective equipment, protection for the extremities, protective clothing, protective shields and barriers, electrical protective equipment, and personal hearing protective equipment.

Inspection

Inspect compressor prior to any use. Check for external damage that might have occurred during transit. Be careful of moving parts then test pulley by turning it freely by hand. Report any damage to delivery carrier immediately.

WARNING

CAUTION

Make sure pallet-mounted compressors are firmly secured to the pallet before moving. NEVER attempt to move a compressor that is not secure as serious injury or property damage could occur.

A forklift may be necessary for unloading the Polar Air compressor. Use all forklift safety measures and require a certified forklift operator. Refer to figure 1 for safe unloading procedure.

6


Forklift Safety

1. Make sure lift operator stays aware while moving compressor.

2. Be sure load is secure and well balanced before moving the compressor.

3. Make sure forks are fully engaged and level before lifting or moving compressor.

4. Keep load as low as possible and observe safe operating practices.

Lifting Safety

1. Carefully inspect all lifting equipment and make sure it is in good condition. Rated capacity should exceed compressor weight. Make sure lifting hook has a functional safety latch or equivalent and is properly attached to lifting feature.

2. Make sure lifting points are in good condition and tighten any loose nuts or bolts before lifting.

3. Use provided lifting feature or appropriate sling. A sling must be used when moving compressor with a helicopter or other air borne equipment. Be sure to follow OSHA standards 29

CFR 1910 Subpart N.

4. Use guide ropes or equivalent to prevent twisting or swinging of the compressor while it is in the air and NEVER attempt to lift in high winds. Keep compressor as low to the ground as possible.

5. Keep persons away and make sure no one is under the compressor while it is lifted.

6. Only use lifting features provided for entire compressor package. NEVER use bolts or other hooks on invididual components to move the compressor.

7. Make sure to put compressor on a level surface that can support the weight of the compressor and loading equipment.

WARNING

Do not operate unit if damaged during shipping, handling or use.

Damage may result in bursting and cause injury or property damage.

7


Installation

Area

1. Install compressor in a clean, dry and well-lit area. Be sure installation area can maintain a temperature range between 35˚ - 110˚ F.

CAUTION

If ambient temperature drops below 32˚F, be sure to protect safety/relief valves and drain valves from freezing. NEVER operate compressor with temperatures below 15˚F or above 125˚F.

2. Allow sufficient space around compressor for maintenance access and adequate airflow. Mount unit with pulley towards wall and leave a minimum of 15 inches of clearance.

3. Use shims to level compressor if installation area is not flat. This will avoid excessive vibration and premature pump wear.

DO NOT install compressor in boiler room, paint spray room, or area where sandblasting occurs. Make sure inlet air is away from exhaust fumes or other toxic, noxious or corrosive fumes or substances.

DANGER

4. If acid is used in operating environment or air is dust laden, pipe intake to outside, fresh air. Increase pipe size by one size for every 20 feet of run. Be sure to install protective hood around intake filter.

5. In operating environments where excessive water, oil, dirt, acid or alkaline fumes are present, a TEFC

(totally enclosed, fan cooled) motor is recommended. Check nameplate for motor type.

6. Insulate cold water or other low temperature pipes that pass overhead to avoid condensation dripping on compressor which could cause rust and / or motor shorting.

Piping

Safety Steps

1. Install appropriate flow-limiting valves as necessary according to pipe size(s) used and run lengths. This will reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302(b)(7).

2. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly, in accordance with the manufacturer’s recommendations.

8


Piping / Tank Installation

1. Place tank feet on 1/4” thick rubber pads. Thicker padding will increase vibration and the possibility of cracking the tank or other unit damage. Do not place unit on dirt floor or uneven surface.

2. Fasten anchor bolts snugly but do not overtighten so normal vibration will not damage unit.

DANGER

Compressor unit is top heavy and must be bolted to solid, flat surface to avoid falling and premature pump wear. Splash lubrication will not operate properly if unit is not level.

3. Use a flexible connector between compressor tank and piping system to minimize noise, vibration, unit damage, and pump wear.

4. Install appropriate ASME code safety valves and make sure piping system is equipped with adequate condensate drains. See figure 2. Refer to figure 3 for recommended closed loop installation.

Never install a shut-off valve such as a glove or gate valve, between the pump discharge and the air tank unless a safety valve is installed in the line between valve and pump.

WARNING

5. Make sure any tube, pipe or hose connected to the unit can withstand operating temperatures and retain

pressure.

WARNING

Never use plastic (PVC) pipe for compressed air. Serious injury or death could result.

6. Never use reducers in discharge piping. Keep all piping and fittings the same size in the piping system.

9


Minimum Pipe Size For Compressed Air Lines

(Pipe size shown in inches)

PLAN VIEW

Closed loop system in piping from air supply to minimize pressure drop and two directions.

Air Drop

(typ.)

Air Drop: to minimize condensation in air drop

ELEVATION

Water trap with drain

To Air Tool

From Compressor

From

Compressor

7. For permanent installations of compressed air systems, determine total length of system and select correct pipe size. Make sure underground lines are buried below frost line and avoid areas where condensation could build up and freeze.

8. Test entire piping system before underground lines are buried. Be sure to find and repair all leaks before using compressor.

WARNING

Never exceed recommended pressure or speed while operating compressor.

Electronic Auto Drain

(if equipped)

One auto drain can be used for multiple compressor units. Install necessary piping with appropriate fittings.

10


1. Plug auto drain into 120V outlet.

2. Set timers to desired settings. See figure 4. If drain is used for multiple units, increase timer settings as

needed.

3. Use test button to check proper operation. Refer to maintenance section for proper care.

Electronic Safety

Be sure only trained and authorized personnel install and maintain this compressor in accordance with all applicable federal, state and local codes, standards and regulations. Follow all NEC (National Electric

Code) standards especially those concerning equipment grounding conductors.

DANGER

1. Follow all NEC and local codes for electrical wiring. Allow only authorized Polar Air service person or certified electrician to install electrical components.

2. Put unit on dedicated circuit and make sure no other electrical equipment is wired into it. Failure to wire unit on independent circuit can cause circuit overload and/or imbalance in motor phasing. Install proper No

Fuse Breaker (NFB) according to kW output of compressor.

3. Ensure incoming service has adequate ampere rating.

4. Ensure supply line has the same electrical characteristics (voltage, cycles and phase) as the electric motor.

5. Refer to amp load information on motor tag and use correctly sized wiring. Be sure to consider distance between power supply and machine.

6. Install surge protection device between power supply and compressor motor.

7. Make sure to install properly sized breakers and fuses.

8. The unit must be properly grounded. DO NOT connect ground wire to air or cooling lines.

11


Improperly grounded electrical components are shock hazards. Make sure all the components are properly grounded to prevent death or serious injury.

DANGER

9. Make sure proper overload protection for the motor is installed.

Wiring Installation

Install power leads into terminals opposite motor wires.

When wiring unit with magnetic starter, do not install power directly to pressure switch to avoid possible fire and property damage.

WARNING

Ensure power supply and internal wiring is adequate according to voltage and frequency stated on motor nameplate and starter. Voltage should not vary more than 12% to ensure proper operation of compressor.

Single Phase Motors - No Magnetic Starter

1. Connect first power lead to 1L1.

2. Connect second power lead to 3L2.

3. Connect ground wire to existing motor ground wire.

Single Phase Motors - With Magnetic Starter

1. Connect first power lead to 1L1. Leave existing jumper wire installed. See Figure 6.

2. Connect second power lead to 3L2. Leave existing

3. Connect ground wire to ground lug.

4. Ensure all wiring and terminals are properly tightened.

N O

N

P

R

O

Q

S

12


Three Phase Motors

( See figure 7 )

1. Connect first power lead to 1L1.

2. Connect second power lead to 3L2.

3. Connect third power lead to 5L3.

4. Connect ground wire to existing motor ground wire.

5. Check for proper motor rotation. When facing motor shaft, pulley should turn counterclockwise. If rotation is

reversed, then switch two power leads.

CAUTION

Ensure wiring is installed according to voltage required for proper motor operation (220V or 460V).

Operation

Safety Rules

1. Make sure all operators receive product training, read and understand all instructions.

Keep all flammable, combustible, poisonous and noxious materials away from operating area. Make sure there are no oily rags, trash, leaves, litter or other combustible materials in operating area. Keep suitable, fully charged fire extinguishers nearby when servicing and operating the compressor.

WARNING

13


2. NEVER allow modifications to compressor structure or controls.

3. Keep all ignition sources away from exposed electrical parts.

4. Keep all persons clear of compressor during start-up and operation.

5. NEVER operate the compressor with the fan, coupling or other guards removed.

6. DO NOT engage in horseplay with air hoses as death or serious injury may result.

7. Make sure to provide adequate ventilation and use proper lubricant while operating the compressor. If lubricant or other combustible substances are spilled, clean up immediately.

8. When checking or adding lubricant or when refilling air line anti-icer systems with antifreeze compound, shut off compressor and allow it to cool. Keep sparks, flames and other ignition sources away and DO NOT permit smoking in the vicinity.

9. Stop compressor and disconnect power if a hazardous condition arises.

10. Wear snug fitting clothing and confine long hair when around compressor. Keep all body parts and clothing away from couplings, flywheel and other moving parts of the equipment.

Keep all persons away from the discharge opening of hoses or tools or other points of compressed air discharge. If the machine is installed in an enclosed area, be sure to vent the relief valve outside of the structure or to an unoccupied area.

DANGER

11. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer’s rated safe operating pressures for these items.

12. Make sure all hose connections are adequately secured to prevent tools or hose ends from being accidentally disconnected.

Start-Up

1. This unit is shipped with pump break-in oil and should be ready to operate. Be sure to check for proper oil level before operating the compressor. Oil should be in center of site glass. See figure 8.

NOTICE

Use only Airbase Industries oil (PN: APOL03000G1). Use of any other product will cause product damage and void the warranty.

2. Check for proper belt tension. There should be 1/2 inch slack. Refer to maintenance section if adjustment is

necessary.

14


Always make sure main power is off before touching belts or other moving parts of compressor.

WARNING

3. Lightly push power switch to make sure system is working.

4. If motor shaft is not turning counter clockwise, disconnect power to terminal block then exchange any two of the three power leads. Re-check rotation.

Figure 9: Continuous run feature

Continuous Run Feature (

if equipped

)

For heavy use applications such as sandblasting, the continuous run feature is available. This feature keeps main feed line open to eliminate numerous motor starts/stops and to help cool pump.

To engage continuous run feature, open ball valve found by following copper tubing across cylinder heads to tank.

See figure 9.

Stop continuous run feature by closing valve so compressor will start and stop according to pressure switch.

Maintenance

Safety Steps

Disconnect, tag and lock out power source then release all pressure from the system before attempting to install, service, relocate or perform ANY maintenance.

WARNING

1. Make sure repairs are done in a clean, dry, well lighted and ventilated area.

2. When cleaning, use air pressure less than 30 PSI (2.1bar). NEVER use flammable solvents for cleaning purposes. Also use effective chip guarding and personal protective equipment per OSHA standard 29 CFR

1910.242 (b).

15


3. Relieve all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before refilling optional air line anti-icer systems with antifreeze compound.

4. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, or otherwise damaged insulation. Replace terminals that are worn, discolored or corroded. Keep all terminals and pressure connectors clean and tight.

5. Keep all body parts and any hand-held tools or other conductive objects away from exposed live parts of the electrical system. When making repairs or adjustments, stand on a dry, insulated surface and DO NOT contact any other portion of the compressor.

6. DO NOT leave compressor unattended with exposed electrical components. Be sure to tag and disconnect all power if temporary absence is necessary.

Compressor components can become hot during operation. Avoid bodily contact with hot liquids, hot surfaces and sharp edges and corners.

CAUTION

Belt Adjustment

Be sure to relieve all system pressure then lock out power and tag compressor to prevent unexpected movement of the unit.

WARNING

Inspect belt tension after first 30 hours of operation then every 30 days.

1. Proper belt tension is determined by pressing on belt midway between motor pulley and flywheel. There should beapproximately 1/2 inch of deflection.

2. Adjust belt tension as needed by loosening the four motor frame nuts then adjusting single bolt head on belt tensioner. See figure

11. Remember to tighten motor bolts after adjustment is

made.

3. Always replace all belts with the same brand, at the same time.

Make sure belts are unimatched. Do not replace belts

independently.

16


4. Do not splash lubricating oil on belts or pulleys when adjusting or replacing belts.

Changing Oil

All units are shipped with break-in oil. Change oil within first 50 hours or 30 days of operation, whichever comes first.

DO NOT use automotive type oil.

NOTICE

Use only Airbase Industries Oil (PN: APOL03000G1). Use of any other product will cause product damage and void the warranty.

Change oil every 90 days or if oil becomes milky.

Safety Valve

NEVER attempt to regulate or tamper with safety valve. Valve is sealed and certified by ASME code and is designed to relieve system pressure when necessary.

DANGER

Check proper operation of safety valve before each use. Refer to figure 12. If valve does not open manually, replace immediately.

Discharge pressure is generally set at 175 PSI (12.1 bar). DO NOT attempt to open valve while machine is under pressure.

Tank

Drain daily.

If unit is equipped with electronic auto drain:

1. Check daily to ensure proper operation.

2. Clean filter daily. Refer to figure 13.

17


Maintenance Schedule

Problem

Low air pressure

Overheating

Troubleshooting Chart

Possible Causes Resolutions

1. Clogged inlet filter

2. Air leak(s) in system

3. Application exceeds rated air output of

compressor

4. Cylinder head valves not sealing

5. Insufficient power

1. Disassemble valve, clean thorougly

2. Use soapy water to locate leaks, replace or tighten threaded parts

3. Check CFM requirements, change tool or use compressor with higher air output

4. Remove valves from cylinder head, repair or replace as necessary

5. Check power supply, rewire as necessary

1. Duty cycle exceeded

2. Improper rotation

3. Head valve(s) not seating properly

4. Blown cylinder head gasket(s)

5. Restriction in head, intercooler or check valve

6. Low oil

1. Keep duty cycle at 60/40 to maintain pump life

2. When facing flywheel, ensure counterclockwise rotation

3. Clean or replace

4. Replace gasket(s)

5. Clear blockage

6. Add oil. Ensure oil level is at middle of site glass. See figure 8.

NOTICE

Use only Airbase Industries Oil

(PN:APOL03000G1). Use of any other product will cause product damage and void the warranty.

7. Dirt in intercooler fins or cylinder fins

8. Poor ventilation / ambient temperature too

high

7. Use low pressure air to blow dirt away from

compressor

8. Increase ventilation around operating area.

Ensure compressor has adequate clear space from walls and other possible obstructions. Ambient temperature should not exceed 110˚ F.

18


Warranty Statement

EATON COMPRESSOR AND FABRICATION CO., INC. (and each of its subsidiaries, including POLAR AIR COMPRESSORS, INC.) makes the following Warranties:

1.

THAT EACH BARE COMPRESSOR PUMP UNIT TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 5 YEARS FOR THE UNIT FROM THE

DATE OF PURCHASE. Eaton Compressor and Fabrication Co., Inc. (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is necessary, it is the Purchaser’s discretion and obligation (at Purchaser’s expense) to have a redundant UNIT. Warranty repairs shall not include freight costs.

Purchaser is responsible for returning unit to Eaton Compressor and Fabrication Co., Inc. This pump must have Eaton Compressor and Fabrication Co., Inc. lubricant

Synthetic exclusively, the same which must be purchased from Eaton Compressor and Fabrication Co., Inc. (Mixing different brands of oils will void the pump warranty). A service kit must be purchased from Eaton Compressor and Fabrication Co., Inc. for this warranty to apply. Service kits contain an air filter and synthetic oil that must be changed annually. Annual proof of purchase of all oil programs must be maintained by the original purchaser of the compressor pump. If the unit runs out of oil, this warranty is void. Failure to fully comply with this warranty and fully comply with the manual herein will void this warranty.

Exclusions include: service such as OIL CHANGES, FILTER REPLACEMENTS, GASKET TIGHTENING TO CORRECT OIL SEEPAGE or DRIVE BELT TIGHTENING and

VALVE CLEANING and are not covered under warranty.

Warranty shall be void under the following conditions: Failure to routinely change oil and to maintain a clean filter, or exceeding 70% duty cycle resulting in overheating and excessive wear and tear, or exposing electrical components to rain or water, or installing the unit in a hostile environment such as acid vapors or any caustic or abrasive matter that may be ingested into the pump, or installing the unit in an enclosed area where lack of cooling ventilation is present, such as in boiler or equipment rooms where the ambient air exceeds 100˚F.

2.

THAT EACH COMPRESSOR UNIT TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 5 YEARS FOR THE COMPRESSOR PUMP AND 2

YEARS ON THE REMAINDER OF THE UNIT FROM THE DATE OF PURCHASE. The UNIT also carries a 1-year labor warranty. Eaton Compressor and Fabrication Co.,

Inc. (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is necessary, it is the Purchaser’s discretion and obligation

(at Purchaser’s expense) to have a redundant compressor. Warranty repairs shall not include freight costs. Purchaser is responsible for returning unit to Eaton

Compressor and Fabrication Co., Inc. This pump MUST have Eaton Compressor and Fabrication Co., Inc. Lubricant Synthetic exclusively, the same which must be purchased from Eaton Compressor and Fabrication Co., Inc. (Mixing different brands of oil will void this warranty). A service kit must be purchased from Eaton

Compressor and Fabrication Co., Inc. for this warranty to apply. Service kits contain an air filter and synthetic oil that must be changed annually. Annual proof of purchase of all oil programs must be maintained by the original purchaser of the compressor unit. If the unit runs out of oil, this warranty is void. Failure to fully comply with this warranty and fully comply with the manual herein will void this warranty.




3.

GENERAL PROVISIONS: Eaton Compressor and Fabrication Co., Inc. (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is necessary, it is the Purchaser’s discretion and obligation (at Purchaser’s expense) to have a redundant compressor. Warranty repairs shall not include freight costs. If necessary, the Purchaser is responsible for returning unit and/or applicable part(s) to Eaton Compressor and Fabrication Co., Inc.



Further exclusions include failure to fully and completely follow the guidelines set forth in the manual. Of specific note is where a product is used where granite and/ or concrete work is performed or conditions are dusty and the product is required to be housed in a separate room from the adverse conditions where the product has access to fresh air intake.

Parts used for warranty purposes must be supplied by Eaton Compressor and Fabrication Co., Inc. Warranty work will be performed by an approved Eaton Compressor and Fabrication Co., Inc. Technician. If any maintenance (other than routine maintenance) is performed by a non-approved Eaton Compressor and Fabrication

Co., Inc. Technician, written pre-approval must be obtained from Eaton Compressor and Fabrication Co., Inc. to prevent voiding this Warranty. Failure to fully comply with this warranty and fully comply with the manual herein will void this warranty.

All warranties are nontransferable.

The Oil Purchase Program is effective as of January 1, 2011.

19

Splash Lubricated, Air Compressor Pumps


SPLASH LUBRICATED

AIR COMPRESSOR PUMPS

Airbase Industries designs and manufactures products for safe operation. However, operators and maintenance persons are responsibile for maintaining safety. All safety precautions are included to provide a guideline for minimizing the possibility of accidents and property damage while equipment is in operation.

Keep these instructions for reference.

Model Specification Charts . . . . . . . . . . .2

Safety Information . . . . . . . . . . . . . . . . . . . 3

Tag Definitions . . . . . . . . . . . . . . . . . . 3

Basic Guidelines . . . . . . . . . . . . . . . . . 3

Breathable Air . . . . . . . . . . . . . . . . 3

Personal Protective Equipment . . . . . . 4

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . 4

Area . . . . . . . . . . . . . . . . . . . . . . . 4

Piping Safety Steps . . . . . . . . . . . . . 5

Tank Installation . . . . . . . . . . . . . 5

Pump Installation. . . . . . . . . . . . 5

Contents

Operation . . . . . .. . . . . . . . . . . . . . . . .8

Safety Rules . . . . . . . . . . . . . . . . . . . . 8

Start Up . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 9

Safety Steps . . . . . . . . . . . . . . . . . . . . . 9

Belt Adjustment . . . . . . . . . . . . . . . . . . . . 10

Changing Oil . . . . . . . . . . . . . . . .. . . . . . 10

Maintenance Schedule . . . . . . . . . . . . . . . . . 11

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 11

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

AMNU000001 0810


Model

Description

CFM Displacement

CFM @ Pressure (100 psi)

Max PSI

Noise DB(A)


Pump RPM

Bolt Pattern

Dimensions

Weight (lbs.)

L•W•H

(inches)

Belt Type (A or B)

Number of Belts

SINGLE STAGE


APP2V0313S

3HP

13

10.2

145

75

NPT 1/2”

850

8-3/16 x 4-5/8

15 x 10 x 13

60

A

1

APP3Y0518S

5HP

18

14.1

145

75

NPT 1/2”

950

8-1/4 x 5-1/4

18 x 15 x 12

75

A

2

APP2V0732S

7.5HP

32

18

145

74

NPT 3/4”

680

10-1/4 x 5-3/8

18 x 15 x 12

121

B

2

TWO STAGE


Model

Description

CFM

Displacement

CFM @ Pressure

(100 psi)

Max PSI

Noise DB(A)

Outlet

Connection

Pump RPM

Bolt Pattern

Dimensions

L•W•H

(inches)

Weight (lbs.)

APP3Y0521T APP2I0524T APP3Y0732T APP4V1043T APP3Y1544T APP3Y2062T APP4V2598T

5HP - 3cyl

21

18

175

74

NPT 3/4”

895

9-7/8 x 6-1/2

25 x 13 x 18

133

5HP- 2cyl

24

17

175

75

NPT 3/4”

795

7-3/4 x 9

16 x 14 x 19

180

7.5HP

32

24

175

75

NPT 3/4”

830

9-7/8 x 6-1/2 9-1/4 x 9-1/4 13-1/2 x 6-3/4 13-1/2 x 6-3/4

25 x 13 x 18

149

10HP

43

34

175

75

NPT 3/4”

600

28 x 21 x 21

282

15HP

44

35

175

75

NPT 1-1/4”

640

27 x 14 x 27

321

20HP

62

52

175

75

NPT 1-1/4”

640

27 x 14 x 27

369

25HP

98

91

175

79

NPT 1-1/4”

710

13-5/8 x 12

5/8

38 x 29 x 26

684

Belt Type

(A or B)

B B B B B B B

No. of Belts 2 2 2 2 3 3 4

2


Safety Information

This manual contains very important information to know and understand. This is provided for SAFETY and to

PREVENT EQUIPMENT PROBLEMS. To help understand this information, observe the following:

DANGER

Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

NOTICE

Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Notice indicates important information, that if not followed, may cause damage to equipment.

Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment.

Basic Guidelines

1. Allow only trained, authorized persons who have read and understood these operating instructions to use this compressor pump. Failure to follow the instructions, procedures and safety precautions in this manual can result in accidents and injuries.

2. NEVER start or operate the compressor pump under unsafe conditions. Tag the compressor, disconnect and lock out all power to it to prevent accidental start-up until the condition is corrected.

3. Install, use and operate the compressor pump only in full compliance with all pertinent OSHA regulations and all applicable Federal, State & Local codes, standards and regulations.

4. NEVER modify the compressor pump and/or controls in any way.

5. Keep a first aid kit in a convenient place. Seek medical assistance promptly in case of injury. Avoid infection by caring for any small cuts and burns promptly.

Breathable Air

1. NEVER use air from this compressor pump for breathable air except in full compliance with OSHA Standards

29 CFR 1910 and any other Federal, State or Local codes or regulations.

DANGER

Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards on safety equipment.

3


2. DO NOT use air line anti-icer systems in air lines supplying respirators or other equipment used to produce breathable air. DO NOT discharge air from these systems in unventilated or other confined areas.

Personal Protective Equipment

Be sure all operators and others around the compressor and its controls comply with all applicable OSHA, Federal,

State and Local regulations, codes and standards relating to personal protective equipment. This includes respiratory protective equipment, protection for the extremities, protective clothing, protective shields and barriers, electrical protective equipment, and personal hearing protective equipment.

Inspection

Inspect compressor pump prior to any use. Check for external damage that might have occurred during transit. Be careful of moving parts then test pulley by turning it freely by hand. Report any damage to delivery carrier immediately.

WARNING

WARNING

Do not operate unit if damaged during shipping, handling or use.

Damage may result in bursting and cause injury or property damage.

Installation

Area

1. Install compressor pump in a clean, dry and well-lit area. Be sure installation area can maintain a temperature range between 35˚ - 110˚ F.

2. Insulate cold water or other low temperature pipes that pass overhead to avoid condensation dripping on compressor which could cause rust and/or motor shorting

DO NOT install compressor in boiler room, paint spray room, or area where sandblasting occurs. Make sure inlet air is away from exhaust fumes or other toxic, noxious or corrosive fumes or substances.

DANGER

4


3. If acid is used in operating environment or air is dust laden, pipe intake to outside, fresh air. Increase pipe size by one size for every 20 feet of run. Be sure to install protective hood around intake filter.

4. In operating environments where excessive water, oil, dirt, acid or alkaline fumes are present, a TEFC

(totally enclosed, fan cooled) motor is recommended. Check nameplate for motor type.

5. Allow sufficient space around compressor pump for maintenance access. Mount unit with pulley towards wall and leave a minimum of 15 inches of clearance.

6. Use shims to level compressor if installation area is not flat. This will avoid excessive vibration and premature pump wear.

Piping Safety Steps

1. Install appropriate flow-limiting valves as necessary according to pipe size(s) used and run lengths. This will reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302(b)(7).

2. Flow-limiting valves are listed by pipe size and rated CFM. Select appropriate valves accordingly, in accordance with the manufacturer’s recommendations.

Tank Installation

1. Place tank feet on 1/4” thick rubber pads. Thicker padding will increase vibration and the possibility of cracking the tank or other unit damage. Do not place unit on dirt floor or uneven surface.

2. Fasten anchor bolts snugly but do not overtighten so normal vibration will not damage unit.

DANGER

Compressor unit is top heavy and must be bolted to solid, flat surface to avoid falling and premature pump wear. Splash lubrication will not operate properly if unit is not level.

Pump Installation

1. Mount pump to deck of tank then connect main feed port to check valve in tank. See figure 1.

2. For units with centrifugal unloader system, install 1/4” copper tubing from 90˚ elbow (located in front of crankcase) to the unloader port of check valve.

NOTE: If pump is not equipped with centrifugal unloader, install an unloader line from the check valve unloader port to the unloader port of the pressure switch. This will relieve head pressure when unit stops and provide no-load restarting.

Check valve

5


3. Cap fitting on cylinder heads if not using pilot valve for continuous run port.

4. Make sure there is a 1/4” copper tube (unloader tube) installed from tank check valve to unloader on pressure switch. This relieves head pressure when compressor stops for easier restart. See figure 2.

5. Use proper pulley for motor. Refer to Pulley Size Chart for correct sizing.

6. Install belts. There should be 1/2” slack for proper belt tension. See figure 3.

7. Use a flexible connector between compressor tank and piping system to minimize noise, vibration, unit damage, and pump wear.

Pump

Model No.

APP2V0313S

APP3Y0518S

APP3Y0518S

APP3Y0521T

APP2V0732S

APP2I0524T

APP3Y0732T

APP3Y0732T

APP4V1043T

APP4V1043T

APP3Y1544T

APP3Y2062T

APP4V2598T

APP4V2598T

Electric

Motor - Hp

7.5

10

10

15

20

25

5

5

5

7.5

5

5

3

3

Pulley Size Chart

(Pulley size in inches)

1750 RPM

4 Pole Motor

6.4

8.8

9

9

9

11.5

5.5

7.7

6

7

5.5

5.5

5.75

7

3450 RPM

2 Pole Motor

3.2

4.4

4.5

4.5

4.5

5.8

2.75

2.75

2.75

3.5

2.75

3.8

3

3.5

Gas Engine

Hp

13

18

24

28

40

50

8

11

11

13

5.5

6.5

6.5

8

Gas Engine

Pulley Size

3.2

4.4

4.5

4.5

4.5

5.8

3

4

3

4

3

3

3

3.5

NOTICE

Splash lubricated pumps require 550 RPM for proper lubrication. Be sure to size motor and engine pulleys correctly.

6


8. Install appropriate ASME code safety valves and make sure piping system is equipped with adequate condensate drains. See figure 4.

Never install a shut-off valve such as a glove or gate valve, between the pump discharge and the air tank unless a safety valve is installed in the line between valve and pump.

WARNING

9. Make sure any tube, pipe or hose connected to the unit can withstand operating temperatures and retain

pressure.

WARNING

Never use plastic (PVC) pipe for compressed air. Serious injury or death could result.

10. Never use reducers in discharge piping. Keep all piping and fittings the same size in the piping system.

11. For permanent installations of compressed air systems, determine total length of system and select correct pipe size. Make sure underground lines are buried below frost line and avoid areas where condensation could build up and freeze.

12. Test entire piping system before underground lines are buried. Be sure to find and repair all leaks before using compressor.

Ball

Valve

Coalescing Filter with Auto Drain

To Shop

Piping

Air Dryer

Air Tank

Water Drain Valve

Figure 4: Basic Piping Diagram

WARNING

Never exceed recommended pressure or speed while operating compressor.

SCFM

20

40

60

100

125

Minimum Pipe Size For Compressed Air Lines

(Pipe size shown in inches)

25 ft.

3/4

3/4

3/4

1

1-1/4

Length Of Piping System

50 ft.

3/4

1

1

1

1-1/4

100 ft.

3/4

1

1

1

1-1/2

250 ft.

1

1

1

1-1/4

1-1/2

Be sure to install belt guard on compressor unit after pump installation is complete.

WARNING

7


Operation

Safety Rules

1. Make sure all operators receive product training, read and understand all instructions.

Keep all flammable, combustible, poisonous and noxious materials away from operating area. Make sure there are no oily rags, trash, leaves, litter or other combustible materials in operating area. Keep suitable, fully charged fire extinguishers nearby when servicing and operating the compressor.

WARNING

2. NEVER allow modifications to compressor structure or controls.

3. Keep all ignition sources away from exposed electrical parts.

4. Keep all persons clear of compressor during start-up and operation.

5. NEVER operate the compressor with the fan, coupling or other guards removed.

6. DO NOT engage in horseplay with air hoses as death or serious injury may result.

7. Make sure to provide adequate ventilation and use proper lubricant while operating the compressor. If lubricant or other combustible substances are spilled, clean up immediately.

8. When checking or adding lubricant or when refilling air line anti-icer systems with antifreeze compound, shut off compressor and allow it to cool. Keep sparks, flames and other ignition sources away and smoking in the vicinity.

DO NOT permit

9. Stop compressor and disconnect power if a hazardous condition arises.

10. Wear snug fitting clothing and confine long hair when around compressor. Keep all body parts and clothing away from couplings, flywheel and other moving parts of the equipment.

DANGER

Keep all persons away from the discharge opening of hoses or tools or other points of compressed air discharge. If the machine is installed in an enclosed area, be sure to vent the relief valve outside of the structure or to an unoccupied area.

8


11. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer’s rated safe operating pressures for these items.

12. Make sure all hose connections are adequately secured to prevent tools or hose ends from being accidentally disconnected.

Start-Up

1. This unit may or may not contain oil when shipped. Be sure to check for proper oil level before operating the compressor. Oil should be in center of site glass. See figure 5.

NOTICE


2. Check for proper belt tension. There should be 1/2 inch slack. Refer to figure 3, pg. 4.

Always make sure main power is off before touching belts or other moving parts of compressor.

WARNING

3. Push power switch to make sure system is working.

4. Ensure motor rotation is correct. Refer to unit operating instructions if necessary.

Maintenance

Safety Steps

Disconnect, tag and lock out power source then release all pressure from the system before attempting to install, service, relocate or perform ANY maintenance.

WARNING

1. Make sure repairs are done in a clean, dry, well lighted and ventilated area.

2. When cleaning, use air pressure less than 30 PSI (2.1bar). NEVER use flammable solvents for cleaning

purposes.

Also use effective chip guarding and personal protective equipment per OSHA standard 29 CFR

1910.242 (b).

9


3. Relieve all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before refilling optional air line anti-icer systems with antifreeze compound.

Compressor components can become hot during operation. Avoid bodily contact with hot liquids, hot surfaces and sharp edges and corners.

CAUTION

Belt Adjustment

Be sure to relieve all system pressure then lock out power and tag compressor to prevent unexpected movement of the unit.

WARNING

Inspect belt tension after first 30 hours of operation then every 30 days.

1. Proper belt tension is determined by pressing on belt midway between motor pulley and flywheel. There should be approximately 1/2 inch of deflection. Refer to figure 3, pg. 4.

2. Always replace all belts with the same brand, at the same time. Make sure belts are unimatched. Do not replace belts independently.

3. Do not splash lubricating oil on belts or pulleys when adjusting or replacing belts.

Changing Oil

Some units are shipped with break-in oil. Change oil within first 50 hours or 30 days of operation, whichever comes first. DO NOT use automotive type oil.

NOTICE


Change oil every 90 days or if oil becomes milky. High humidity and excessive temperature changes can cause moisture to form in the pump. This moisture will cause oil to break down and become milky. Be sure to check oil regularly for proper lubrication. Make sure to dispose of used parts such as oil and filters in accordance with all applicable regulations.

10


Maintenance Schedule

Problem

Low air pressure

Overheating

Troubleshooting Chart

Possible Causes Resolutions

1. Clogged inlet filter

2. Air leak(s) in system

3. Application exceeds rated air output of

compressor

4. Cylinder head valves not sealing

5. Insufficient power

1. Disassemble valve, clean thoroughly

2. Use soapy water to locate leaks, replace or tighten threaded parts

3. Check CFM requirements, change tool or use compressor with higher air output

4. Remove valves from cylinder head, repair or replace as necessary

5. Check power supply, rewire as necessary

1. Duty cycle exceeded

2. Improper rotation

3. Head valve(s) not seating properly

4. Blown cylinder head gasket(s)

5. Restriction in head, intercooler or check

valve

6. Low oil

7. Dirt in intercooler fins or cylinder fins

8. Poor ventilation / ambient temperature too

high

11

1. Keep duty cycle at 60/40 to maintain pump life

2. When facing flywheel, ensure counter-clockwise rotation

3. Clean or replace

4. Replace gasket(s)

5. Clear blockage

6. Add oil. Ensure oil level is at middle of site glass. See figure 5, pg. 6.

NOTICE

Use only Airbase Industries Oil

(PN:APOL03000G1). Use of any other product will cause product damage and void the warranty.

7. Use low pressure air to blow dirt away from

compressor

8. Increase ventilation around operating area.

Ensure compressor has adequate clear space from walls and other possible obstructions. Ambient temperature should not exceed 110˚ F.


Airbase Industries makes the following WARRANTY STATEMENT:

1.

THAT EACH BARE COMPRESSOR PUMP UNIT TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 2 YEARS FOR THE UNIT FROM

THE DATE OF PURCHASE. Airbase Industries (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is necessary, it is the Purchaser’s discretion and obligation (at Purchaser’s expense) to have a redundant COMPRESSOR PUMP. Warranty repairs shall not include freight costs.

Purchaser is responsible for returning unit to Airbase Industries. This PUMP MUST have Airbase Industries Lubricant Synthetic exclusively, the same which must be purchased from Airbase Industries. (Mixing different brands of oil will void this warranty). A service kit must be purchased from Emax or an Emax dealer for this warranty to apply. Service kits contain an air filter and synthetic oil that must be changed annually. Annual proof of purchase of all oil programs must be maintained by the original purchaser of the compressor pump. If the unit runs out of oil, this warranty is void. Failure to fully comply with this warranty and fully comply with the manual herein will void this warranty.




Airbase Industries shall not be held liable for any malfunction of BARE COMPRESSOR PUMP UNIT caused by failure or improper use and/or maintenance of other compressor components manufactured by others.

2.

GENERAL PROVISIONS: Airbase Industries (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is necessary, it is the

Purchaser’s discretion and obligation (at Purchaser’s expense) to have a redundant compressor. Warranty repairs shall not include freight costs. If necessary, the

Purchaser is responsible for returning unit and/or applicable part(s) to Airbase Industries.



Further exclusions include failure to fully and completely follow the guidelines set forth in the manual. Of specific note is where a product is used where granite and/ or concrete work is performed or conditions are dusty and the product is required to be housed in a separate room from the adverse conditions where the product hasaccess to fresh air intake.

Parts used for warranty purposes must be supplied by Airbase Industries. Warranty work will be performed by an approved Airbase Industries Technician. If any maintenance (other than routine maintenance) is performed by a non-approved Airbase Industries Technician, written pre-approval must be obtained from Airbase

Industries to prevent voiding this Warranty. Failure to fully comply with this warranty and fully comply with the manual herein will void this warranty.

All warranties are nontransferable.

The Oil Purchase Program is effective as of January 1, 2011.

12

APP2I0523T-EC5T

Introduction

In order to receive maximum performance and long life from your compressor, the following instructions should be carefully read and all points regarding installation and operation of the unit should be noted and observed. A careful reading of this manual, prior to connecting anything to the motor of the compressor, will pay dividends in terms of trouble-free operation.

Inspection

Check for possible damage in transit and see that the pulley turns freely by hand. Report any damage to the delivery carrier at once.

Location

Select a clean, dry, and well-lit location. In cold climates, the compressor should be installed in a heated building. Insulate cold water or other low temperature pipes that pass overhead to avoid the possible collection and dripping of condensate onto the compressor and motor that could cause rusting or the motor shorting out.

DO NOT install the compressor in a boiler room, paint spray room, or area where sandblasting is carried on. If air in the area where the compressor is to be installed is acid or dust laden, the compressor intake should be piped to the outside. This intake pipe should increase in size for every twenty (20) feet of run and the intake filters should be installed at the end of the pipes with a hood to protect them from the elements.

Special size filters are required for that pipe.

If the compressor has to be located where the motor will be exposed to appreciable quantities of water, dirt, oil, acid, or alkaline fumes, the motor must be of special construction to avoid rapid deterioration; i.e. TEFC

Unless the base is exactly level, shims will be required. Any space between the base and foot of the tank should be shimmed rather than drawing the foot down, thus placing strain on the unit. When is properly shimmed, vibration will be at a minimum. Also use a ¼’’ or less rubber pad under each foot to help with vibration.

Allow sufficient space around the compressor so that it is accessible from all sides for maintenance. Mount the unit with the pulley side toward the wall, but at least 18 inches from it.

Hooking up the pump

• Mount pump to the deck of the tank. We recommend using angle iron to raise the pump above the deck, to allow for better crankcase cooling.

• Hook up main feed tube from the 3/4’’ flare fitting to the check valve in the tank.

• Run ¼’’ copper tubing from 90 degree elbow (coming out of the front crankcase) to the side of your check

valve.

• Don’t hook up the ¼’’ copper tubing on the top of the cylinder heads unless using a pilot valve.

2

APP2I0523T-EC5T

• Make sure there is a tube from the check valve in the tank to the unloader on the pressure switch.

This will relieve the head pressure when the compressor stops. This will make it easier for the motor when the compressor goes to restart.

• Fill crankcase with Airbase Industries synthetic piston air compressor oil, to the center of the sight glass. (Genuine Airbase synthetic compressor oil is required to maintain your warranty from Eaton and can be purchased over our web site.)

• Size the correct pulley for your motor. Use a 4’’ pulley on a 3450 rpm motor and a 7 3/4’’ pulley on a 1750 rpm motor.

• Install your belts. There should be a ½’’ of play on the belt tension.

• Turn on the motor and check for proper rotation. The pump must run counter clockwise when facing the pulley side of the compressor.

3

APP2I0523T-EC5T

Air intake

The compressor pumps are equipped with intake filters that require no piping. If it necessary to pipe the intake outdoors, see paragraph 3, “Location”

Pipe Connection

A flexible connector should be used between the compressor tank and building piping or connection to after cooler or other similar equipment in order to minimize noise, vibration, vibration damage, and wear and tear.

Caution

• Never install a shut-off valve, such as a glove or gate valve, between the compressor and discharge opening and the receiver unless a safety valve is installed in the line between this valve and the compressor.

• Never operate the pump at pressures or speeds in excess of those recommended by the factory.

(900rpm or 175 psi)

Tank

Tank feet should be place on vibration isolator pads available through your dealer. Anchor bolts should be gently snugged, but not tight, to allow for vibration. Remember, the bolt is only a guide to hold the compressor in place. Do not over tighten the legs of the tank against the pads…it will damage your tank.

Caution: Do not set tank on dirt. Over time, the tank will tilt causing the pump to fail from in adequate lubrication.

Starting

• Check the oil level before starting

• Turn compressor over a few revolutions by hand to make sure that everything is free.

• Check the belt tension

• Remove tools, rags, and any other objects from the vicinity of the compressor

• Never put hands on the belt of idle units, unless the motor is switched off and locked out

• Note the direction of the arrow on the flywheel and be sure that the direction of rotation is correct when the machine is started. Correct direction is counter-clockwise when standing facing the flywheel. Air should be drawn through the intercooler onto the cylinders for maximum cooling.

Service

Operation and Care

Oil should be changed within the first 50 hours or 30 days of use, which ever comes first. “Use only genuine Airbase

Industries synthetic compressor oil in your Eaton piston compressor”.

Warning!!

Under no circumstances should you use AUTOMOTIVE TYPE OIL. RepeatDO NOT USE

AUTOMOTIVE OIL.

• Oil should be changed every 90 days. Oil level

• If oil is milky, it should be changed

• Inspect air filters weekly and change as needed

4

APP2I0523T-EC5T

Daily Care

• Check oil level in crankcase and, if necessary, add sufficient oil to bring to (but not above) halfway level on the sight glass (without the motor running)

• Drain air receiver, drop legs

• Stop, look, and listen a moment for any unusual noise, failure to compress, overheating, vibration, or belt slippage. Correct before damage of a serious nature can develop.

Monthly Care

• Check and tighten all bolts as required

• Check air connections and joints for leaks

• Check “V” belts for any possible misalignment and tightness

Maintenance-Trouble Shooting-Repairs

SLOW PUMPING OR INSUFFICIENT PRESSURE CAN BE CAUSED BY:

• Clogged inlet filter-(disassemble and clean thoroughly)

• Leaks in airlines, valves, fittings, etc.-(Located using soapy water if necessary; replace or tighten threaded parts)

• Compressor too small for equipment being operated-(Check air requirements an add to compressor capacityconsult dealer )

• Leaking head valves-(Remove hold-down covers and remove valves for examination. Repair or replace faulty valves)

Overheating

Compression of air generates heat, much of which is dissipated as air passes over the intercooler and/or after cooler. Overheating can be caused by:

• Pump running backwards- (reverse rotation) Proper rotation is counter clockwise when facing the

flywheel

• One or more heads valves is failing to seat properly

• Blown cylinder head gasket

• Restriction in head, intercooler, or check valve

• Lack of oil-(check oil level)

• Dirt in intercooler fins or cylinder fins-(blow out with air)

• Poor ventilation and high-room temperature.

5

APP2I0523T-EC5T

LIMITED FIVE-YEAR WARRANTY

EATON COMPRESSOR & FABRICATION WARRANTS EACH COMPRESSOR UNIT

TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 5

YEARS ON THE COMPRESSOR FROM THE DATE OF PURCHASE. (Eaton Compressor & Fabrication is not responsible for downtime during warranty service. If downtime is necessary, Purchaser is required to have redundant compressor.) Warranty repairs shall not include freight costs. Purchaser is responsible for returning unit to Eaton Compressor.

Service such as OIL CHANGES, FILTER REPLACEMENTS, GASKET TIGHTENING TO

CORRECT OIL SEEPAGE or DRIVE BELT TIGHTENING and VALVE CLEANING are not covered under warranty.

Warranty shall be void under the following conditions:

•

•

•

•

•

•

Failure to routinely change oil and to maintain a clean filter.

Exceeding 65% duty cycle resulting in overheating and excessive wear and tear.

Exposing electrical components to rain or water.

Installing the unit in a hostile environment such as acid vapors or any caustic or abrasive matter that may be ingested into the pump.

Installing the unit in an enclosed area where lack of cooling ventilation is present. such as in boiler or equipment rooms where the ambient air exceeds100oF.

Parts used for warranty purposes must be supplied by EatonCompressor.

Warranty work will be performed by an approved Eaton Compressor Technician.

Eaton Compressor & Fabrication 1000 Cass Drive, Clayton, Ohio 45315 (877) 283-7614

6

7

8

APP2I0523T-EC5T

Item Part No.

1 BOLT011

Part Description

BOLT, HEX, M16-2.0-125MM

UNIT QTY

PCS 1

32 GASKET079

33 COVER010

34 FITTING035

35 WASHER013

36 BOLT012

37 NUTS015

38 WASHER016

39 COVER009

40 FILTER057

41 HOUSING027

42 GASKET086

43 RETAINER007

44 N/A

45 N/A

46 DIPPER001

47 BEARING005

48 ROD010

49 PISTON008

50 PIN010

51 RING019

2 NUTS013

3 WASHER012

4 KEY002

5 FLYWHEEL007

6 BOLT012

7 WASHER013

8 COVER005

NUT, HEX , 16MM-2.0

WASHER, LOCK 16MM

KEY, FLYWHEEL

FLYWHEEL, 2 BELT


8MM COPPER WASHER

FRONT COVER

9 GASKET035

10 SEAL010

11 BEARING006

12 CRANK006

GASKET, FRONT COVER

OIL SEAL, CRANKSHAFT

BEARING, CRANK, FRONT

CRANKSHAFT

13 CRANKCASE006 CRANKCASE

14 GASKET048 SIGHT GLASS GASKET

15 SIGHTGLASS004 OIL SIGHT GLASS

16 WASHER013 8MM COPPER WASHER

17 BOLT012

18 BEARING012


BEARING, CRANK, REAR

19 SHIM002

20 GASKET036

ADJUST SHIM, CRANK

GASKET, BRG HOUSING

21 FITTING035 FITTING, PLUG 3/4’’

22 CONNECTOR030 CONNECTOR, PLATE

23 WASHER013

24 BOLT013

PCS 1

PCS 2

PCS 2

PCS 1

PCS 1

PCS 1

PCS 1

PCS 1

8MM COPPER WASHER PCS 4

BOLT, ALLEN HD M8-1.25-30MM PCS 4

25 UNLOADER001

26 GASKET046

27 COVER007

28 BREATHER002

29 WASHER013

30 BOLT014

31 VALVE024

CENTRIFUGAL UNLOADER

GASKET CENTRIF. HOUSING

UNLOADER COVER

BREATHER, CRANKCASE

8MM COPPER WASHER

BOLT, ALLEN M6-1.0-25MM

VALVE CENTRIF. UNLOADER

PCS 1

PCS 1

PCS 1

PCS 1

PCS 4

PCS 4

PCS 1

PCS 1

PCS 1

PCS 1

PCS 1

PCS 6

PCS 6

PCS 1

PCS 1

PCS 1

PCS 1

PCS 1

PCS 1

PCS 1

GASKET, ACCESS COVER

SIDE COVER

FITTING, PLUG 3/4’’

8MM COPPER WASHER

PCS 1

PCS 1

PCS 1

PCS 6


NUT, WING, M6-1.0

WASHER 6MM, FLAT

COVER, FILTER, AIR, INTAKE

PCS 6

PCS 1

PCS 1

PCS 1

FILTER ELEMENT, AIR, INTAKE PCS 1

BASE, FILTER, AIR,INTAKE

GASKET, FILTER, AIR, INTAKE

PCS 1

PCS 1

RETAINER, FILTER, AIR, INTAKE PCS 1

COMES WITH 48 PCS 4

COMES WITH 48

OIL DIPPER

BEARING, ROD

ROD, CONNECTING

PCS 4

PCS 2

SETS 2

PCS 2

PISTON, HIGH PRESSURE, SMALL PCS 1

WRIST PIN HIGH PRESSURE

SNAP RING, PISTON

PCS 1

PCS 4

Item Part No.

52 PIN008

78 WASHER013

79 SHIM002

80 BOLT019

81 VALVE055

82 FITTING016

83 FITTING028

84 BOLT012

85 WASHER013

86 COVER008

87 GASKET041

88 STOPPER002

89 RETAINER003

90 VALVE041

91 GASKET040

92 ORING013

93 BOLT017

94 SPRING001

95 RETAINER006

96 UNLOADER002

97 NUTS014

98 RETAINER004

99 VALVE040

100 STOPPER001

101 RETAINER005

102 PISTON007

9

53 RING012

54 RING011

55 GASKET044

56 CYLINDER011

57 GASKET033

58 WASHER014

59 BOLT016

60 COOLER001

61 GASKET043

62 FITTING028

63 VALVE008

64 WASHER013

65 BOLT013

66 ELBOW002

67 WASHER013

68 BOLT013

69 BUSHING057

70 ELBOW003

71 TEE001

72 LINE106

73 WASHER015

74 BOLT018

75 GASKET034

76 FITTING035

77 COOLER002

EC5 (5 HP INLINE) PARTS IN DETAILS

Part Description

WRIST PIN LOW PRESSURE

UNIT QTY

PCS 1

PISTON RING LOW PRESS.

PISTON RING HIGH PRESS.

GASKET, CYL, BOTTOM

CYLINDER

GASKET, HEAD

10MM COPPER WASHER


AFTERCOOLER

GASKET, AFTERCOOLER

¼ STREET L

POPOFF VALVE 200 PSI

8MM COPPER WASHER

BOLT, ALLEN HEAD M8-1.25-30MM

ELBOW, AFTERCOOLER

8MM COPPER WASHER

BOLT, ALLEN HEAD M8-1.25-30MM

PCS 2

PCS 1

PCS 2

PCS 2

BUSHING, BRASS, 3/8MALE X1/4”FEMALE PCS 2

ELBOW, 1/4”M TO 6MM COMPRESS.

PCS 1

TEE, 1/4 MALE PIPE, 6MM, COMPRESSION SETS 1

LINE, CROSSOVER, 6MM PCS 1

WASHER, LOCK, 12MM

BOLT, M12-1.75-75MM

GASKET, INTERCOOLER

PLUG, PIPE, 3/4

INTERCOOLER

PCS 8

PCS 8

PCS 2

PCS 2

PCS 1

SETS 1

SETS 1

PCS 1

PCS 1

PCS 1

PCS 6

PCS 6

PCS 1

PCS 2

PCS 1

PCS 1

PCS 2

8MM COPPER WASHER

ADJUST SHIM, CRANK

BOLT, M8-1.25-95MM

POPOFF VALVE 70 PSI

Fitting, Bushing, 3/4M X 1/4F

¼ STREET L


8MM COPPER WASHER

COVER, VALVE

GASKET, VALVE, COVER

STOPPER,VALVE,RETAINER .650

RETAINER, EXH. .800 MEDIUM

VALVE, EXHAUST

COPPER GASKET

ORING, UNLOADER, PLUNGER

BOLT, UNLOADER, PLUNGER

SPRING, UNLOAD, 1.1 LONG

RETAINER, UNLODER

FORK, UNLOADER

NUT, LOCKING, M6-1.0

RETAINER, INT., 1.100 LONG

VALVE, INTAKE

STOPPER, VALVE, RETAINER,.860

RETAINER, INT..625 SHORT

LOW PRESSURE PISTON

PCS 2

PCS 2

PCS 2

PCS 2

PCS 2

PCS 5

PCS 2

PCS 2

PCS 2

PCS 4

PCS 2

PCS 4

PCS 1

PCS 1

PCS 1

PCS 2

PCS 2

PCS 2

PCS 2

PCS 2

PCS 2

PCS 3

PCS 1

PCS 1

PCS 1

No results