Gasoline Portable Air Compressor Installation, Operation and Maintenance Manual

Transcription

1 45920; 5 HP Honda, 8.3 PC, 8 Gal., Wheel Tank 4592; 5.5 HP Honda,3.3 PPC, 8 Gal.,2 Wheel Tank 45922; 9 HP Honda, 6.2 PPC, 8 Gal.,2 Wheel Tank Proven Performance Gasoline Portable Air Compressor Installation, Operation and Maintenance Manual To the Owner: Thank you for purchasing a NorthStar Air Compressor. Your machine is designed for long life, dependability, and the top performance you demand! Please take time now to read through this manual so you better understand the machine s operation, maintenance and safety precautions. Everyone who operates this machine must read and understand this manual. The time you take now will prolong your machine s life and prepare you for its safe operation. Enjoy the exceptional performance of your NorthStar Air Compressor, the industry leader! The manufacturer reserves the right to make improvements in design and/or changes in specifications at any time without incurring any obligation to install them on units previously sold. Quick Facts Engine Oil Engine is shipped without oil. Fill before starting. Use SAE 0W-30 motor oil. Pump Oil Check pump oil level before starting. Use non-detergent pump oil (part # 35605). Air Filter Replacement air filter part number is AB for Item #45920 & 4592, and filter #35409 for Item #45922 Maximum Pressure Item #45920 & #4592 maximum pressure = 30 psi. Item #45922 maximum pressure = 75 psi Maintenance Schedule Engine: Oil: change after first 20 hours, then annually or every 00 hours. Spark Plug: clean every 00 hrs., replace annually or every 300 hrs. Air Filter: clean weekly, replace annually or every 000 hrs. Tank: Compressor Pump: Manual# M35644K.5 Drain water daily Oil: change after first 50 hours, then every 3 months or 500 hours. Read and understand all manuals before operating. Any Questions, Comments, Problems or Parts Orders NorthStar Product Support Call Hours: Monday - Friday 7:00 AM to 5:00 PM Saturday 7:30 AM to :30 AM Central Time

2 Table of Contents Important Safety Instructions 2 Maintenance 6 Receipt and Inspection 2 Kits & Service Parts 6 Machine Component 3 Exploded View / Component List 7-0 Identification Assembly 4 Pneumatic Schematic Diagrams Operation 5 Troubleshooting 2 Safety DEFINITIONS DANGER! WILL cause DEATH, SEVERE INJURY or substantial property damage. WARNING! CAN cause DEATH, SEVERE INJURY or substantial property damage. CAUTION! WILL or CAN cause MINOR INJURY or property damage. GENERAL SAFETY PRECAUTIONS ALWAYS wear eye protection when operating or servicing compressor. NEVER operate where flammable or explosive liquids or vapors such as gasoline, natural gas and solvents are present. NEVER remove, paint over, or deface decals. Replace any missing decals. NEVER operate with guards or shields removed, damaged or broken. NEVER operate indoors, this compressor intended for outdoor use only. Avoid inhaling exhaust fumes, risk of asphyxiation. Exhaust fumes are deadly. NEVER add fuel when the product is operating or hot. NEVER directly inhale compressed air. NEVER over-pressurize the receiver tank or similar vessels beyond design limits. NEVER use a receiver tank or similar vessels that fail to meet the design requirements of the compressor. NEVER drill into, weld or otherwise alter the receiver tank or similar vessels. NEVER remove, adjust, bypass, change, modify or make substitutions for safety/relief valves, pressure switches or other pressure control related devices. NEVER use air tools or attachments without first determining the maximum pressure recommended for that equipment. NEVER point air nozzles or sprayers toward people or animals. NEVER touch the compressor pump, engine or discharge tubing during or shortly after operation. These parts become hot. BREATHING AIR PRECAUTION NorthStar air compressors are not designed, intended or approved for breathing air. Compressed air should not be used for breathing air applications unless treated in accordance with all applicable codes and regulations. Receipt and Inspection Before signing the delivery receipt, inspect for damage and missing parts. If damage or missing parts are apparent, make the appropriate notation on the delivery receipt, then sign the receipt. Immediately contact the carrier for an inspection. All material must be held in the receiving location for the carrier s inspection. Delivery receipts that have been signed without a notation of damage or missing parts are considered to be delivered clear Subsequent claims are then considered to be concealed damage claims. Settle damage claims directly with the transportation company. If you discover damage after receiving the air compressor (concealed damage), the carrier must be notified within 5 day of receipt and an inspection must requested by telephone with confirmation in writing. On concealed damage claims, the burden of establishing that the compressor was damaged in transit reverts back to the claimant. Read the compressor nameplate to verify it is the model ordered, and read the motor nameplate to verify it is compatible with your electrical conditions. Make sure electrical enclosures and components are appropriate. 2

3 Machine Component Identification Machine Component Identification.) Engine - Engine is NOT shipped with oil. Refer to engine owners manual for proper viscosity and capacity of oil for your engine. 2.) On/Off Switch - Make sure switch is at ON position when starting engine (Model 8.3 PC has a kill switch). 3.) Compressor Air Filter - Make sure your air filter is clean and particle free. See pump exploded view for replacement filter part number. 4.) Belt Guard - Covers the belt, motor pulley and flywheel. NEVER operate compressor without belt guard. 6.) Lifting Eyes - Also use as tie down locations. 7.) Ball Valve - 3/8 NPT. 9.) Unloader - Lift knob to relieve pressure when starting the engine. 0.) Pneumatic Tires - Keep tire pressure at 20 psi for easy movement..) Pressure Gauge - Easy to read liquid filled gauge. 2.) ASME Safety Valve - This valve automatically releases air if the tank pressure exceeds the preset maximum. 3.) Discharge Tube - This tube carries compressed air from the pump to the check valve. This tube becomes very hot during use. To avoid the risk of severe burns, never touch the discharge tube. 4.) Engine Control - Location of choke, engine speed and fuel valve Model 8.3 PC Item # &4 Models 3.3 PPC, 6.2 PPC Items #4592, #

4 Assembly Model Assemble tire on air compressor as shown. Model 4592 & Assemble tires on air compressor as shown. Allow /6 movement between jam nut and wheel. Allow /6 between end of bolt and tank. 5/8 Nut 5/8 Jam Nut Wheel Axle Pin Cap Wheel 5/8 Bolt Item # Description Qty Wheel 375 5/8 Axle 3032 Pin 2 Model Item # Description Qty Wheel /8 x 3.5 Bolt /8 Jam Nut /8 Nut Cap 2 Model 4592 & /6 Bolt Right Handle Grip Rubber Foot 5/6 Flange Bolt Nut /6 Nut Left Handle 5/6 Flat Washer Attach rubber feet as shown Attach handles with grips as shown. Item# Description Qty Item # Description Qty 225 Rubber Foot Left Handle /6 X Flange Bolt Right Handle /6 Flange Nut Grip /6 X 2 Flange Bolt /6 Flange Nut /6 Flat Washer 4 4

5 Sight Glass Drain INITIAL START-UP.Pump is shipped with oil. Remove the oil cap and check pump oil level. Add SAE 30 non-detergent pump oil (NorthStar part #35605), if necessary. Hand tighten breather cap. 2. Turn pressure relief knob to engine start position. Engine start Breather Cap Engine run 3. The engine is shipped without oil. Refer to the engine manual for oil capacity and viscosity recommendations Refer to engine manual to start your engine. 5. Once the engine has started, move the pressure relief knob to the engine run position. CAUTION! Unusual noise or vibration indicates a problem. Do not continue to operate until you identify and correct the source of the problem. Operation WARNING! Never disconnect threaded joints with pressure in the tank. NOTE: Reduce tank pressure below 0 psi, then drain moisture from tank daily to avoid tank corrosion. Drain moisture from tank(s) by opening the drain petcock located at the bottom of the tank. COMPRESSOR LUBRICATION CAUTION! Do not operate without lubricant or with inadequate lubricant. Use of compressor without lubricant or inadequate lubricant voids all warranties. Synthetic Lubricants Synthetic lubricants are recommended after 50 hour break-in. Compressor life is greatly increased with the use of synthetic lubricants. CAUTION! If you will be using synthetic lubricant, all downstream piping material and system components must be compatible. Suitable Viton, Teflon, Epoxy (Glass Filled), Oil Resistant Alkyd, Fluorosilicone, Flourocarbon, Polysulfide, 2-Component Urethane, Nylon, Delrin, Celcon, High Nitrile Rubber (Buna N. NBR more than 36 Acrylonite), Polyurethane, Polyethylene, Epichlorohydrin, Polyacrylate, Melamine, Polypropylene, Baked Phenolics, Epoxy, Modified Alkyds ( indicates trademark of DuPont Corporation) Not Recommended Neoprene, Natural Rubber, SBR Rubber, Acrylic Paint, Lacquer, Varnish, Polystyrene, PVC, ABS, Polycarbonite, Cellulose Acetate, Latex, EPR, Acrylics, Phenoxy, Polysulfones, Styrene Acrylonitile (San), Butyl Alternate Lubricants. You may use petroleum-based lubricant that is premium quality, does not contain detergents, contains only anti-rust, anti-oxidation, and anti-foam agents as additives, has a flashpoint of 440 F (227 C) or higher, and has a autoignition point of 650 F (343 C) or higher. See the petroleum lubricant viscosity table below. The table is intended as a general guide only. Heavy duty operating conditions require heavier viscosities. Refer specific operating conditions to NorthStar Product Support at Monday - Friday 7:00 AM-5:30 PM, Saturday 7:30 AM-:30 AM Central Standard Time. CAUTION! Do not attach air tools to open end of the hose until start-up is completed and the unit checks out OK. 6. Run the unit for 30 minutes, with ball valve open, to break in pump parts. 7. Close the ball valve to shut off air flow. The compressor is now ready for use. 8. After 50 hours of operation change the compressor oil. Temperature Viscosity Grade around Compressor ISO SAE Below 40 F (4 C) F to 80 F (4 C to 27 C) F to 00 F (27 C to 37 C) Pump Capacities. Refer to the following table for crankcase capacity Item # Crankcase capacity oz 4592, oz 5

6 Maintenance WARNING! Disconnect spark plug wire from spark plug and release air pressure from system before performing maintenance. NOTE: All compressed air systems contain maintenance parts (e.g. lubricating oil, filters, separators), which are periodically replaced. These used parts may be, or 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 position and locations of parts during disassembly to make reassembly easier. The assembly sequences and parts illustrated may differ for your particular unit. Daily or before each operation Weekly Monthly 3 months or 500 hours 2 months or 000 hours Check lubrication levels. Fill as needed. Drain receiver tank condensate. Check for unusual noise or vibration. Ensure belt guards and covers are securely in place. Ensure area around compressor is free from rags, tools, debris, and flammable or explosive materials. Check safety/relief valves by pulling rings. Replace safety/relief valves that do not operate freely. Inspect air filter element. Clean if necessary. Inspect for air leaks. Squirt soapy water around joints during compressor operation and watch for bubbles. Tighten fittings if necessary. Clean exterior. Change petroleum lubricant while crankcase is warm. Replace air filter element. DRIVE BELT Belts will stretch in normal use. Properly adjusted, a 5 pound force applied to the belt between the motor pulley and the pump will deflect the belt about /2. TO ADJUST DRIVE BELT:. Remove the belt guard cover. 2. Loosen the four fasteners holding the engine/motor to the compressor. 3. Shift the engine/motor in the proper direction. The belt must be properly aligned when adjustment is made. 4. To align belt, lay a straight edge against the face of the flywheel touching the rim at two places. 5. Adjust flywheel or motor pulley so that the belt runs parallel to the straight edge. 6. If necessary, use a gear puller to move the pulley on the motor shaft. Tighten set screw after pulley is positioned. 7. Check for proper belt tension (see diagram). 8. Tighten the four fasteners holding the engine/motor to the compressor. 9. Attach belt guard cover. Service Parts Air filter (Item #45920 & 4592): Part #AB Air filter (Item #45922): Part #35409 Non-detergent Oil: Part #

7 Exploded View Rev. K.5 Model 8.3 PC (Item #45920) Ref Description Model Part # Qty Belt Guard ALL Rotating Equip. Decal ALL Guard Bracket ALL Set Screw (/4-20) ALL Warning Decal ALL Sheave, AK49H-3/4 ALL Engine, Honda GC60 ALL Hot Muffler Decal ALL Recoil Decal ALL Carbon Monoxide Decal ALL 6022 PC Honda Decal ALL Decal ALL Receiver Tank ALL Bridge Pin ALL /8 Axle ALL Wheel ALL Safety Valve, 50 psi ALL Nameplate ALL General Decal ALL Air Gauge, Liquid Filled ALL Ref Description Model Part # Qty 22 Bumper ALL Honda Bushing ALL Threaded Clamp ALL Cushioned Clamp ALL Idle Solenoid Cable ALL Drain Valve ALL /8 NPT Elbow ALL Unloader Valve ALL /8 Comp. Sleeve ALL /8 Comp. Nut ALL /8 Copper Tube ALL /8 Comp. /2 Elbow ALL /8 Ball Valve ALL /8 Elbow ALL Rubber Grip ALL /8 Plug ALL Tube Cap ALL Operation Instr. Decal ALL Pump, B2800B ALL Belt, A53 ALL Belt Guard Cover ALL

8 Exploded View Rev. K.5 Model 3.3 PPC (Item #4592), Model 6.2 PPC (Item #45922) Item Description Model Part # Qty Belt Guard ALL Decal ALL GX Honda Decal ALL Decal ALL Belt Guard Cover ALL Rotating Equip. Decal ALL Guard Bracket Belt, A Pump, B3800B Pump, B4900B Left Handle ALL Right Handle ALL Rubber Grip ALL Drain Valve ALL Bumper ALL Gallon Tank ALL /8 NPT Male Elbow ALL /8 Ball Valve ALL Decal Air Gauge, Liquid Filled ALL /8 x 3.5 Bolt ALL Tire ALL /8 Jam Nut ALL /8 Nut ALL Item Description Model Part # Qty 24 Safety Valve, 50 psi Safety Valve, 200 psi Unloader, psi Unloader, psi /8 Compression Sleeve ALL /8 Compression Nut ALL /8 Copper Tube /2 Elbow ALL Engine, Honda GX Engine, Honda GX Cushioned Clamp Idle Solenoid Cable CO Warning Decal ALL Threaded Clamp ALL Honda Bushing ALL Nameplate Operation Instr. Decal ALL Warning Hot Decal ALL Sheave, AK54H-3/ Sheave, AK59H Set Screw (/4-20) Set Screw (5/6-8)

9 77900 & 7790 Pump Assembly Ref Description Model Part # Qt y Head ALL AB Head Bolt (M8 x 45mm SHCS) ALL AB Aftercooler Gasket ALL AB Aftercooler, 8mm ALL AB Aftercooler Bolt (M6 x 20mm SHCS) ALL AB Head Gasket ALL AB Valve Plate Assembly ALL AB Cylinder Gasket ALL AB Reducer ALL AB AB Cylinder, Cast Iron Sleeve AB Crankcase Gasket ALL AB Cover N.D.E. ALL AB Bearing Cover Gasket ALL AB Bearing ALL AB Oil Sight Glass ALL AB Crankcase AB AB Cylinder Bolt (M6 x 20 mm SHCS) ALL AB Oil Drain Plug ALL AB Cankcase Bottom Bolt (M5 x 5mm HHCS) ALL AB Oil Pan AB AB Ref Description Model Part # Qty 2 Oil Pan Gasket AB AB Crankshaft AB AB Cover D.E. ALL AB Oil Seal ALL AB Screw, Reverse Thread ALL AB Flywheel Washer ALL AB Flywheel, 280 mm AB Flywheel, 350 mm AB Bearing Housing Bolt (M6 x 5mm SHCS) ALL AB Connecting Rod AB AB Circlip ALL AB Wrist Pin ALL AB Piston, Aluminum AB AB Piston Ring, ROF ALL AB Piston Ring, ROS ALL AB Piston Ring, AC ALL AB Breather Cap AB Filter Assembly ALL AB Filter Assembly Bolt ALL AB

10 (M6 x 25mm SHCS) Complete Gasket Kit AB AB

11 77902 Pump Assembly Item Description Part # Qty Pump Head AB Head Bolt (M8 x 55mm SHCS) AB Intercooler Gasket AB Intercooler/Aftercooler Bolt (M8 x 20mm SHCS) AB Gasket AB Aftercooler AB Reducer AB Head Gasket AB Valve Plate Assembly AB Cylinder Gasket AB Cylinder, Cast Iron Sleeve AB Frame Gasket AB Cover N.D.E. AB Bearing Cover Gasket AB Bearing AB Oil Sight Glass AB Crankcase AB Cylinder Bolt AB Crankcase Plug AB Crankcase Bolt (M5 x 5 HHCS) AB Crankcase Pan AB Crankcase Gasket AB Crankshaft AB Nut AB Oil Seal AB Cover D.E. AB Item Description Part # Qty 27 Cover Bolt (M6 x 5 SHCS) AB Flywheel, 350 mm AB Flywheel washer AB Screw, Reverse Thread AB Half Bearing AB Connecting Rod AB Wrist Pin AB H.P. Piston, Aluminum AB Circlip AB Piston Ring ROF AB Piston Ring ROS AB Piston Ring AC AB Rod Bolt AB L.P. Piston, Aluminum AB Wrist Pin AB Piston Ring ROF AB Piston Ring ROS AB Piston Ring AC AB Oil fill plug AB Intercooler AB Safety Valve AB Air Filter Assembly Air Filter Intake Manifold Complete Gasket Kit AB

12 Pneumatic Schematic Diagram Items & PUMP (Item #45920) 7790 PUMP (Item #4592) IDLE DOWN UNLOADER SAFETY RELIEF VALVE 4 GALLON TANK 4 GALLON TANK SAFETY RELIEF VALVE Item IDLE DOWN UNLOADER SAFETY RELIEF VALVE 4 GALLON TANK 4 GALLON TANK

13 Troubleshooting This section provides a list of the more frequently encountered compressor malfunctions, their causes and corrective actions. Some corrective actions can be performed by the operator or maintenance personnel, and others may require assistance of a qualified electrician or Service Center. PROBLEM Engine does not start. Air delivery drops off. Compressor does not come up to speed. Compressor is slow to come up to speed. Compressor will not unload cycle. Compressor will not unload when stopped. Excessive starting or stopping. Moisture in crankcase, milky substance in oil. Oil in discharge air. Safety/relief valve pops. Low interstage pressure. High interstage pressure. POSSIBLE CAUSE A.) Low Oil Shutdown B.) Cold Engine C.) No Fuel D.) Engine not turned ON E.) Spark plug wire not attached F.) Compressor viscosity too high for ambient temperature. G.) Belt tension too tight or sheaves not aligned. H.) Air leaks in discharge piping. I.) Compressor components leaky, broken, loose. J.) Loose flywheel or motor pulley, excessive end play in motor shaft or loose drive belts. K.) Leaking check valve or check valve seat blown out. L.) Clogged or dirty inlet and/or discharge line. M.) Defective safety/relief valve. N.) Pressure switch unloader leaks or does not work. O.) Inadequate ventilation around flywheel. P.) Leaking, broken or worn inlet unloader parts at check valve. Q.) Excessive condensation in receiver tank. R.) Detergent lubricant in crankcase. S.) Light duty cycle. T.) Lubricant level too high. U.) Worn cylinder finish. V.) Low pressure inlet valve leaking. W.) High pressure inlet valve leaking. POSSIBLE CAUSE A,B,C,D,E H, I, J, L, M, N, P F, G, J, K F, G, J, K, L H, L, N, P H, L, N, P N, Q, S R T L, M, N W V POSSIBLE SOLUTION Fill engine with the adequate amount of oil. Choke engine to start. Add gas to engine. Make sure fuel shutoff valve is open Place ON/OFF switch in the ON position. Attach spark plug wire to spark plug. Drain existing lubricant and refill with proper lubricant. Check tension/ alignment. Check tubing connections, Tighten joints or replace as required. Inspect components. Clean or replace as required. Check flywheel, motor pulley, crankshaft drive belt tension/alignment. Replace or repair as required. Replace check valve. Clean or replace. Replace. Realign stem or replace. Relocate compressor for better air flow. Inspect parts and replace as required. Drain receiver tank. Replace with proper lubricant. Increase duty cycle. Drain excess lubricant. Deglaze cylinder with 80 grit flex-hone. Inspect, clean or repair as required. Inspect, clean or repair as required. 3