DEVILBISS Air Compressor Manual L0311218
102D-1 L0311218
User Manual: DEVILBISS DEVILBISS Air compressor Manual DEVILBISS Air compressor Owner's Manual, DEVILBISS Air compressor installation guides
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OWNERS MANUAL FOR PERMANENTLY LUBRICATED AIR COMPRESSOR MODEL NO. ,RlO2D-1 (For Home Use Only) tl'r 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 15AMPS QuickActing 2 Gallon C10'2D-1 --3.0 2,2 4.0 1 3/4" 1 1/4" 110-120 15AMPS QuickActing 2 Gallon *A circuitbreaker ispreferred. Useonly 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 identificationofRepair 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 I MGP-102D-2 2/1/94 I I TABLE OF CONTENTS Page WARRANTY ........................................................ 3 SAFETYGUIDELINES .......................................... 4 WARNING CHART ............................................... 4-5 GLOSSARY......................................................... 5 UNPACKINGINSTRUCTIONS .............................. 5 STORAGE ........................................................... 5 DUTYCYCLE ...................................................... 5 DESCRIPTION OFOPERATION ........................... 6 Page Locationof Air Compressor ........................... ExtensionCords ........................................... GroundingInstructions.................................. AirHose ........................................................ 6 6 6 7 OPERATINGPROCEDURES ............................... 7 TROUBLESHOOTINGGUIDE .............................. 8 AIR COMPRESSOR DIAGRAM AN D PARTS LIST ................................................ COMPRESSOR PUMP DIAGRAM AN D PARTS LIST ............................................. HOWTO ORDER REPAIR PARTS ..................... INSTALLATION AN DBREAK-IN PROCEDURES .................................................... 9-10 11-12 13 6 In the unlikely event you should have a problem with this product or if you are missing a ny 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, 2 Ext. 2 ONE LIMITED YEAR FROM WARRANTY DATE OF PURCHASE All merchandise manufactured by De Vilbiss Air Power Company is warranted to be free ofdefects 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, *airtools, accessories and serviceparts. De Vilbiss 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. i RESPONSIBILITYOFORIGINALPURCHASER(InitialUser):I Q Retain original sales receipts as proof of purchase for warranty work. [3 Use reasonable care in the operation and maintenance of the product as described in the Owners Manual(s). {3 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. [3 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. [3 If the purchaser does not receive satisfactory results from the Authorized Warranty Service Center, the I I II .... ; Air Power Company. I THIS WARRANTYDOESNOTCOVER: q I [3 Merchandise sold as, reconditioned, floor models and/or display models sold "as is", any damaged or incomplete equipment sold "as is". [3 Merchandise used as "rental" equipment. [3 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. [3 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. [3 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. [3 Repair and transportation costs of merchandise determined not to be defective. {3 Cost associated with assembly, required oil, adjustments or other installation and start-up cost. {3 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 ._xclusion or limitation of incidental or con_e_lT._t_tiale_ien,_ve_bta'wsaJ_o_i|oldilati_tt_aqr_l_e, tbf_y are warranted WAR, PA_'OI__ states 213 IndustrialDrive • Jackson TN 38301-9615 • Telephone: 1o800_88-2468, Ext.2 • for a period of 45 da_lp#or MESS FOR A FAX: 1-800-888- do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to 3 I I SAFETY GUIDELINES Thismanual contain s information that is important for you to know an d 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. - NOTE Information for preventing damage to equipment, informationthat you should pay special attentionto. HAZARDS CAN OCCUR IF EQUIPMENT IS NOT USED PROPERLY. PLEASE READ THE FOLLOWING CHART. WHAT TO LOOK FOR WHAT COULD HAPPEN HOW TO PREVENT IT Hot Parts 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. Flammable Vapors It is normal for the motor and pressure switch to spark, i The air compressor must onlybe used in wellventilated A spark can ignite flammable vapors from gasoline or areas, free of gasoline or solvent vapors. solvents, causing a fire or explosion. Do not operate the compressor while you are carrying it, or in the spray area. Compressed Air Corn pressed air can propel dust, dJrtor 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 accessoripscan cause damage or risk of bursting, 4 Check the manufacturer's pressure rating for air tools and accessories. Regulatoroutlet pressure must never exceed the maximum pressure rating. WHAT TO LOOK FOR WHAT COULD HAPPEN HOW TO PREVENT EJectricity Your air compressor is powered by electricity. Like any other electrically powered device, if it is not used properly it may cause electrical shock. IT AJways unplug the air compressor prior to maintenance or repair. Never use the air compressor in the rain. Always plug the cord into an erectrical 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 andfollow 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 eq uipment. GLOSSARY SCFMorCFM: measurement StandardCubicFeetperMinute;aunitof of air delivery. PSIG or PSh Pounds I per square inch gauge, I 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 I Grasp the handle and lift the air compressor out of the carton. Remove the styrofoam and/or cardboard and discard. I STORAGE I When you have finished using the air compressor 1. Set the "ON/OFF" switch to "OFF" and unplug the 3. Protecttheelectricalcordandairhosefromdamage cord, by winding them loosely around the air compressor, 2. Relieveallpressurefromtheaircompressorheadand 4. Storetheaircompressorinacleananddrylocation. 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 I DESCRIPTION Air Compressor Pump: To compress air, the piston moves up and down in the cylinder. On the downstroke, air isdrawn 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 valvecontrols 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 adiustable oressure valve to release air during ooeration. OF OPERATION I Accumulator Tank: Your accumulator tank isequipped with a relief (pop-off) valve to prevent an over pressure condition inthe tank. This 2 gallontank isnot 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 willknow 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, USEA PRESSURE GAUGE. I 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 allowfor proper cooling. Clean or blow off dust or dirt that collects on the air compressor. A clean air compressor runs cooler and provides Iongerservice. The ventilationopeningson your air compressor are necessary to maintain properoperatingtemperature. Do not place rags or other containerson 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 an d 8 AWG may also be used. DO NOT USE 16 OR 18 AWG. 6 GROUNDING INSTRUCTIONS RISK OF ELECTRICAL SHOCKI In the event of a short circuit, grounding reduces the riskof shock by providing an escape wire for the electdc 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. Inspectthe plug and cord before each use. Do not use if there are signs of damage. IMPROPER GROUNDING CAN RESULT IN ELECTRICAL SHOCK. I INSTALLATION AND BREAK-IN 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. PROCEDURES I Air Hose The air hose attached to you r 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. DONOTREPLACE THE HOSE WITH STANDARD HOSE 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. THAT IS NOT EQUIPPED WITH THE PRESSURE ADJUSTING VALVE. 120 VoltModels White Do not allow hose to become kinked or pinched at any time. This is importantto avoid damage to your compressor and to maintain pressure adjusting valve control. lS AMP PLUG OUTLET _E_" GROUNDED _ GROUNDING .jI PIN _ 120 Volts, 15 Amps I 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 M UCH AIR PRESSURE COULD CAUSE AN AIR TOOL OR VEHICLE TIRE TO RUPTURE OR EXPLODE. CAREFULLY FOLLOWSTEPS 5AND 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 aircompressoroutlet pressure must never exceed the maximum pressure rating. 6. Slowly increasethe pressure settingof the adjustable pressure valve. You should be ableto hear and feel air pressure being relieved by the adjustable pressure valve. If pressure is not being relieved, turn the air compressor offimmediately. The pressurevalvemust 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 ordevice. 7 TROUBLESHOOTING GUIDE I VOLTAGE SOURCES, MOVING PARTS OR COMPRESSED AIR SOURCES ARE EXPOSED WHEN REPAIRING THE COMPRESSOR. PERSONAL INJURY CAN OCCUR. UNPLUG THE COMPRESSOR BEFORE AI-rEMPTING ANY REPAIRS. PROBLEM CAUSE SOLUTION Air Leaks Hose fitting loose. Tighten fitting. Compressor isnot delivering enough air. Prolonged Motor will not run. excessive use of air. Decrease the amount of air usage. Your com3ressor is not large enough for the air requiremeat. 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. 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. Extension cord is wrong length or gauge. Check the extension cord. Loose electrical Check wiring connection inside terminal box connections. Faultymotor. High discharge pressure. Cannot be adjusted lower. Have checked at a local Service Center. Adjustable pressu re valve not functioning. RISK OF BURSTING. DO NOT OPERATE THE COMPRESSOR IF THIS PROBLEM EXISTS. ADJUSTABLE PRESSURE VALVE MUST BE REPLACED. 8 I Air Compressor I Diagram 7 1 TO TANK 9 2 4 10 5 6 21 12 11 18 Y 13 14 / 17 15 *POWER CORD (GREEN) GROUND WIRE o / 27 Slide #19 over #7 as shown. Make sure that no part of #7 tube touches #21 or #14 shroud when assembled. 9 I Parts List KEY NO. / * * * + / + * PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CAC-1196 CAC-4323 CAC-1289 CAC-4111 CAC-1342 DAC-163 DAC-168 SSS-16 15 * 16 > 17 > 18 19 20 21 / CAC-1285 CAC-4322-1 DAC-162 DAC-167 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 PlateAssembly "O" Ring Outlet Tube Rod Assembly Screw 3/8-16 x 1/25 LG hex socket flat head (torque to 350 in/Ib) Cylinder Sleeve EndbellAssembly 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) CordAssembly 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. I I Compressor Pump Diagram I TO PUMP-,_--- t I \ 11 I Parts List KEY NO. 23 24 25 26 * 27 28 29 3O 31 33 * 34 * 35 PARTNUMBER DESCRIPTION CAC-1206 CAC-4324 CAC-4076 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 SafetyValve Hose Connection Nipple Drain Cock Screw, self tapping Recess Bumper SSP-6102 SSP-3305-NI TIA-4150 H-2105 SS-1286 SS-2707 SSH-8 H-2099 * 12 KK_4949 NOT ILLUSTRATED Air Chuck Adapter Isolator Kit includes items 3, 4, 6, 13, 16, 34, 35, 27 I I Service Notes I 13 I 14 Service Notes I I Service Notes I 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 unit. Warranty Service Center Directory" is included with your When ordering repair parts from your local Authorized always give the following information: • • Service Center, Model number of your compressor Part number and description you wish to purchase of the item 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. 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. Model No. Date Code No. MFG No. DeVilbiss Air Power Company • 213 Industrial Drive • Jackson, TN 38301-9615
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