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Instruction and Maintenance Manual

3 Phase - Belt Driven Compressors IMPORTANT ──── Make certain that persons who are to use this equipment thoroughly read and understand this Instruction Manual prior to operation. PV0614

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CONTENTS

Chapter 1 Technical Specifications

1.1 Parts and Features …………………..………………………………….……3

1.2 General Information …...…………………………………..…………………4

Chapter 2 Operating the Air Compressor

2.1 Important Safety Instructions …...…………..……….…………...…………8

2.2 Preparation Before Starting ….……..…………………………………….…9

Chapter 3 Maintenance of the Air Compressor

3.1 Regular Maintenance ……...……………………………...…………....…14

Chapter 4 Trouble-Shooting for the Air Compressor

4.1 Trouble-Shooting ………..……………………………………….……….…17

Appendixes

Limited Warranty Policy………..………………….………………….…………23

Please read and understand this manual before operating the compressor. Failure to do so could result in

death, severe injury and/or substantial property damage.

This manual should be considered a permanent part

of the compressor and should remain with it if resold.

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INTRODUCTION

This Owner’s Manual is intended to comply with all Australian Occupational or Workplace Health and Safety

Regulations regarding the manufacturer’s provision of information to the owner or purchaser of work plant. The

information is correct at the date of publication.

APPLICATION

Your air compressor is a single stage, oil lubricated, and air cooled reciprocating air compressor. It is typically

supplied as a compact, self-contained, air receiver (tank) mounted unit that is automatically regulated and driven by

a 3 phase electric motor.

The compressor is intended to provide compressed air in a multitude of applications, for example, to power

pneumatic tools, operate air dusters and spray guns, inflate tires, and supply air for pneumatic valves and actuators.

It is commonly used as the primary source of compressed air for home garages, workshops, service stations, tyre

shops, factories, farms, mobile service vehicles, and so on. Supplementary duties can include furnishing

compressed air at an isolated location not serviced by the regular shop air system, and standby service when

larger compressors are shut down.

Air discharged from an oil lubricated compressor typically contains small amounts of oil, water and particulates

amongst other contaminants. Virtually all applications require treatment of the compressor’s output air to make it

suitable for the end use. Air quality treatments such as filtration and drying are the most common requirements

together with pressure regulation. The use of compressed air lubricators to protect pneumatic tools is also

commonplace nowadays. Failing to install appropriate compressed air treatment equipment will likely result in

damage to pneumatic machinery or spray painted finishes.

Where installed, compressed air filtration and/or drying equipment should be located downstream from the air

receiver tank and ahead of any pressure regulator. Lubricators, on the other hand, should be installed as the last

stage of treatment and located behind or downstream from any pressure regulator.

FUNCTION

The pressure switch turns on the motor when the air receiver tank is at or below the minimum “cut-in” pressure.

The compressor then runns until the tank pressure reaches the maximum “cut-out” pressure whereupon the

pressure switch turns the motor off. Air will then be heard (for some seconds), escaping from the unloader valve

(in the base of the pressure switch) releasing residual air pressure in the discharge pipe and on top of the pistons in

the compressor pump. Thereby allowing the compressor to re-start easily, when next required.

The pressure switch is factory preset with cut-in and cut-out pressures of approximately 120 psi and 150 psi,

respectively. This range is ideal for the vast majority of compressed air applications as most pneumatic tools have

been designed for use with a supply (line pressure) of 90 psi. (6bar). Unless necessary for a special application,

line pressures of more than 90 psi. (6bar) are not recommended.

In the event that a pressure switch were to fail to turn the motor off at the prescribed cut-off pressure, then the

safety valve will protect the air receiver tank against over pressurizing by automatically releasing air when the

pressure exceeds its preset value (ie 150psi [10bar]) . Air receiver tanks are designed and manufactured to

satisfy the requirements of Australian Standards and all Australian Occupational or Workplace Health and Safety

Regulations.

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Chapter 1 Parts & Features

DESCRIPTION

(1) Oil level sight glass (6) Safety cage

(2) Tank Pressure Gauge (7) Electric motor, air intake

(3) Pressure Switch On / Off (8) 3 phase contactor (wall mount)

(4) Non Return Valve (NRV) (9) Oil drain bung

(5) Air filters (10) Lifting Points

IMPORTANT ─ Improper operation or maintenance of this air compressor could

result in serious injury and/or property damage, thoroughly read and

understand this Instruction Manual prior to operating the air compressor.

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2

2

4

10

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1

5

3

9

7

4

Sight glass - Check Daily The compressor oil level can be viewed through the sight glass; the compressor must be on a level surface. The top of the red dot indicates the full mark the bottom of the red dot indicates the low mark. Always ensure that the oil level is correct before operating the compressor.

If the oil is low add Scorpion Compressor oil or equivalent Aircol PD68.

Drain air tank – Daily

A drain valve is fitted to the bottom of the air receiver tank to permit the release of water condensation that

would otherwise corrode the tank and damage pneumatic devices.

Loosen the drain nut and allow any condensed water to escape, once all the air and moisture has been

released, finger tighten only the drain valve.

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Don’t Turn the Compressor on and off at the Wall

Use the Pressure switch – On / Off

The pressure switch automatically controls the power to the motor and

operates the pressure relief valve. It also allows for manual operation via

the Push/Pull - On/Off switch on top of the pressure switch.

The pressure switch is factory set to turn the compressor on when the tank

pressure drops below 120 psi and turn itself off again when the tank is full.

You will notice that every time the unit reaches maximum pressure and

turns itself off (or if the unit is manually turned off); there is a short release

of high pressure air from under the pressure switch.

This is the pressure relief valve venting the air contained within the delivery

tube (the pipe which connects the compressor pump to the non return

valve). Failure to vent the pressurized air between the pump and the tank

will cause excessive current draw on startup which may lead to motor

failure. For this reason always turn the compressor On and Off via the

pressure switch.

The delivery tube:

Supplies compressed air

from the pump to the tank.

Only Operate the Compressor on a Flat Surface Maximum Tilt

The maximum safe operating angle in any direction is 15° degrees.

Do not operate the compressor on inclines in excess of 15° degrees. Serious damage to pump components may result

from insufficient lubrication.

Never use the air compressor on a rooftop or elevated position that could allow the unit to fall or be tipped over.

Always disconnect the power before moving.

The pressure relief valve:

Vents pressure when the

unit is turned off.

The Non Return Valve:

Prevents any back flow from the tank.

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Power supply / 3 phase, 50Hz It is essential that the air compressor has an adequate power supply. The air compressor should be operated on a dedicated 3 phase 415 volt circuit.

The compressor must be connected to a properly grounded circuit of adequate capacity.

• Should you intend to use an air tool for a long durations ensure that the out put of the compressor (know as the

FAD or Free Air Delivery) well exceeds the air consumption of the tool being used.

• Remember that your compressor has been designed with a 50% duty cycle in mind; continuous operation may

cause it to overheat and result in serious mechanical damage to pump components. You should consider a

larger or screw type compressor for long term or continuous duty applications.

• Do not use extension cords. Using an extension lead on a compressor can cause voltage drop,

overheating the motor and leading to appliance damage or even fire.

• As your Compressor has an air cooled motor as well as an air cooled pump which draws in atmospheric air it is

important not to run the compressor in confined areas with poor ventilation or on loose surfaces such as dirt,

dust or sand, otherwise abrasive particles will be sucked into the air stream and cause the premature wear of

components.

• Your air compressor is not water proof; do not attempt to use or store it in the rain, snow or any other

environment with extreme conditions. It has been designed for use and storage indoors.

• Used and maintained correctly, your Compressor will provide many years of reliable service.

• Your Compressor has been manufactured to a high standard in order to ensure a long service life. Ultimately

the realization of the intended service life requires the operator to observe all instructions and servicing

requirements as described in this manual.

• Always wear approved protection equipment such as safety glasses with side shields, ear muffs and gloves

when operating the compressor or using compressed air. Wear a face mask or respirator when spraying,

blowing down or otherwise creating airborne mists or dust.

• Never point any nozzle or sprayer toward any part of the body or at other people or animals.

• Do not operate the air compressor if any guards or covers are missing, damaged or not installed correctly as

the compressor may start automatically. Ensure all maintenance is carried out by qualified personal.

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• Never allow children, pets or untrained personal to “play” with compressed air.

• Keep children, pets or unauthorized personal away from the compressor at all times.

• Compressed air can contain carbon monoxide, hydrocarbons and/or other poisonous contaminants that can

cause death or serious injury. The air compressor is not designed, intended or approved for breathing air. Do

not use compressed air for breathing air applications without proper treatment. Do not use the compressor for

any gas other than air.

• High voltage electricity can cause death or serious injury. All electrical installation or repair work must be

carried out by a licensed electrician.

• DISCONNECT POWER SUPPLY BEFORE SERVICING.

• Do not stand on the compressor or use it as a handhold.

• High pressure air can cause death or serious injury. Do not bypass, modify or remove the safety valve. Do

not operate the compressor with a faulty safety valve or pressure gauge.

• Do not direct the air stream at body, high pressure air can stir up dust and debris that may be harmful.

Release air slowly when draining condensation or depressurizing the compressor. Do not connect the

compressor to air handling equipment that cannot withstand the compressor’s maximum design pressure (refer

to the tank nameplate).

• Rusted, cracked or damaged air receiver tanks can explode and cause death or serious injury and must be

replaced. Drain tank daily or after each use through the valve located at bottom of the tank.

• Release compressed air from tank before servicing, do not weld drill or otherwise modify the air receiver tank.

• Do not spray flammable liquids in a confined area. Do not smoke while spraying where sparks, flames or

other ignition sources (including the compressor) are present.

• Do not direct paint or other sprayed material at the compressor. Locate the compressor as far away from the

spraying area as possible to minimize overspray accumulating on the compressor and/or clogging it’s air filters.

• Motors, electrical equipment and controls can cause electrical arcs that may ignite a flammable gas or vapor.

Do not operate or repair the compressor in or near a flammable gas or vapor. Do not store flammable liquids

or gases in the vicinity of the compressor.

• Before attempting to install, maintain, repair, store or transport the compressor, switch off the unit, tag and lock

out the power supply and carefully release all air pressure from receiver tank, air hoses and/or piping.

• Do not permit anyone to operate the compressor without proper instruction.

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Chapter 2 Operating the Air Compressor

2.1 IMPORTANT SAFETY INSTRUCTIONS

IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND OR PROPERTY DAMAGE.

READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING.

HAZARD WHAT CAN HAPPEN HOW TO PREVENT IT

� Water directed at electrical connections or switches, or objects connected to an electrical circuit, could result in a fatal electrical shock.

� Moisture or a liquid of any kind may conduct electricity and could result in a fatal electrical shock.

The air compressor is not waterproof.

� Never attempt to clean the air compressor while it is running. Direct any water or spray away from electric outlets and switches.

� Keep your air compressor out of the elements and well sheltered from rain, snow, dew, water or mist of any kind.

� Do not use the compressor with the supply cord damaged or with poor quality connections.

0.5m

� Operating the air compressor in an explosive environment could result in a fire.

� Materials placed against or near the

air compressor can interfere with its proper ventilation causing overheating and possible ignition of the materials.

� Improperly stored paint thinners could

lead to accidental ignition. Thinners improperly secured could get into the hands of children or other unqualified persons.

� Good air flow is important as both the

motor and compressor unit are air cooled. Restrictions to or insufficient air flow will cause overheating.

� Never spray paint in a confined area with the air compressor.

� Operate the air compressor in well

ventilated areas free from obstructions. Equip areas with fire extinguishers suitable for electrical fires. Do not leave nylon material shirts or jumpers on the compressor.

� Store paint thinners and other

flammable liquids in approved containers, in a secure location away from the work area.

� Minimum clearance 0.5m � Maximum ambient operating

temperature 45°C

� This air compressor does not provide breathable air; the air may be contaminated with mineral based oils and other contaminants which poses the risk of serious lung infection and or injury.

� Spraying any material without the use

of a face mask will result in the ingestion of foreign substances.

� Never try to provide breathing air or refill auxiliary breathing apparatus using this compressor.

� Never spray substances in a closed

location occupied by humans or animals always use a face mask when spraying substances.

� Contact with hot surfaces, such as the cylinder head, cooling fins or discharge pipe, could result in serious burns.

� These parts will remain hot for some

time after the compressor is shut down.

� During operation, touch only the control surfaces of the air compressor. Keep children and animals far away from the air compressor at all times. They may not be able to recognize the hazards of this product.

� Allow the air compressor to cool before storage.

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2.2 Preparation before Starting RECEIPT AND INSPECTION

Ensure that adequate lifting equipment is available for unloading and moving the air compressor to the installation site.

Lifting equipment, slings, etc. must be properly rated for the weight of the compressor.

Lift the compressor from the delivery vehicle by the shipping pallet only. Do not use the electric motor lifting eyebolt to lift

the entire compressor. The motor lifting eyebolt is only to be used for removing the motor from the compressor unit.

Do not work or walk under the compressor while it is suspended in the air.

Inspect the compressor upon receipt for any shipping damage or missing parts.

• If any problems are apparent, make an appropriate note on the delivery receipt before signing, then contact

your dealer immediately.

• Do not operate unit it has been damaged during shipping.

• Read the compressor model label to verify it is the model ordered.

• Check the motor nameplate to verify that it is compatible with the available electricity supply.

• Make sure that electrical enclosures and components are appropriate for the installation environment.

UNPACKING Remove the carton and plastic bag that covers the

compressor. Ensure that children do not play with the

plastic bag as it is a breathing hazard. Unbolt the

compressor from the shipping pallet. Do not use the

timber shipping pallet for mounting the compressor.

Using a forklift, lift off the shipping pallet using the lifting

points only and place it close to the 3 phase power outlet.

Fit the air filters and add oil to the pump as necessary.

Fit air tap to end of tank and connect to air supply line

We recommend that you store the packaging for the

duration of the warranty period. If necessary, it will be

easier to return the compressor to the service center.

LIFT WITH CARE AS THE COMPRESSOR IS TOP HEAVY

INSTALLATION Select a clean, dry and well lit area most preferably indoors with plenty of space for proper ventilation, cooling air flow

and accessibility. The air compressor is designed for operation in ambient temperatures of between 0°C (32°F) and

40°C (104°F). Locate the compressor at least 500 mm from walls for adequate air cooling and to allow for

maintenance access. Ensure that the power supply is clearly identified and accessible. Always provide sunshade and

shelter from moisture if the compressor has to be located outdoors.

Bolt the compressor to a firm, level foundation such as a concrete floor that is strong enough to support its weight. Do

not bolt uneven feet tightly to the foundation as this will cause excessive stress on the air receiver tank. Use metal shims

to pack under any “short” feet, if necessary. The use of flexible vibration isolators underneath the mounting feet is highly

recommended and will reduce noise emissions.

LIFTING POINTS

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Noise Considerations

Check the State Workplace Health and Safety Regulations and/or Local Council regulations regarding acceptable noise

levels. To reduce excessive noise, use vibration isolators, relocate the compressor or construct an enclosure or baffle

walls.

Discharge Piping

All piping, fittings, air receiver tanks, and so on connected to the compressor discharge must be certified safe for the

unit’s discharge pressure and temperature. Do not use PVC plastic in the compressed air discharge line. Use pipe

thread sealant on all threads and assemble joints tightly to prevent air leaks and energy wastage.

Mainline piping used to convey air throughout a system should be sized to accommodate the maximum flow rate of the

compressor (also referred to as it’s free air delivery) in accordance with Table 1. Branch piping should be sized in a

similar manner, but the design flow rate should instead be based on the total air consumption of the tools or appliances

running off that branch. To allow for vibration and to prevent piping stresses being transmitted to the

compressor, the connection between the unit’s discharge valve and the mainline piping system should be made using a

flexible air hose or coupling.

Table 1

RECOMMENDED PIPE SIZES FOR COMPRESSED AIR LINES

LENGTH OF PIPLINE (METRES)

FLOW L/MIN

7.5m 15m 22.5m 30m 45m 60m 75m 90m

142 ½” ½” ½” ½” ¾” ¾” ¾” ¾”

283 ½” ½” ½” ¾” ¾’ ¾” ¾” ¾”

425 ½” ¾” ¾” ¾” ¾” ¾” ¾” ¾”

566 ¾” ¾” ¾” ¾” ¾” ¾” ¾” ¾”

708 ¾” ¾” ¾” ¾” ¾” 1” 1” 1”

849 ¾” ¾” ¾” ¾” 1” 1” 1” 1”

991 ¾” ¾” 1” 1” 1” 1” 1” 1”

1132 ¾” 1” 1” 1” 1” 1” 1” 1”

1670 1” 1” 1” 1” 1” 1” 1” 1”

2236 1” 1” 1” 1” 1-1/4” 1-1/4” 1-1/4” 1-1/4”

2830 1-1/4” 1-1/4” 1-1/4” 1-1/4” 1-1/2” 1-1/2” 1-1/2” 1-1/2”

Air hose should be sized in accordance with Table 2, and again with consideration as to whether the hose is a

distribution line or a branch line.

Table 2

RECOMMENDED HOSE SIZES FOR COMPRESSED AIR LINES

LENGTH OF HOSE (METRES)

FLOW L/MIN

7.5m 15m 60m

566 3/8” 3/8” ½”

849 3/8” ½” ½”

1698 ½” ¾” ¾”

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ELECTRICAL CONNECTION

This work must be carried out by a licensed electrician. All 3 phase compressor are not supplied with a power lead or plug. A licensed electrician is required to wire up the

compressor from the wall mounted contactor box, to a dedicated 3 phase electrical outlet, either with a four pin plug or

hard-wired into the electrical supply. The circuit must be of adequate capacity and fitted with a circuit breaker.

Mount the contactor box to the wall as close to the compressor as practical.

Ensure correct direction of rotation:

The installing electrician must ensure that when wired in, the motor

is turning in the correct direction. Failure to obtain the correct

direction of rotation will prevent the fan / flywheel from delivering

the necessary air cooling across the pump.

Electrical Connection

All electrical installation and service work must be performed by a licensed electrician in accordance with all applicable

regulations. The electric motor rating as shown on the motor nameplate and the power supply must have compatible

voltage, phase and frequency characteristics.

The required size of electrical wiring between the power supply and the electric motor varies according to motor power

and other factors, use the table below to understand what power is required to operate each size Compressor.

Adequately sized wiring must be installed to protect against excessive voltage drop during compressor start-up and

running. If connecting other electrical equipment to the same circuit, consider the total electrical load when selecting

the proper wire size. Overheating, short circuiting and fire damage may result from undersize wiring.

NB Portable electric generators are not recommended for operating compressors unless they have ample generating

capacity to provide the requisite starting and running currents without appreciable voltage or frequency drop.

Model:

XRS25

Piston Compressor 50% duty cycle

453L/PM

10 Bar (150 psi)

5.5 HP (4 KW)

415V (3 Phase)

8AMPS (per Phase)

200 L

XRS35


708L/PM

10 Bar (150 psi)

7.5 HP (5.6 KW)

415V (3 Phase)

10AMPS (per phase)

270 L

XRS50


1132L/PM

10 Bar (150 psi)

10HP (7.46 KW)

415V (3 Phase)

13.5AMPS (per phase)

270 L

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OPERATION

Before operating the air compressor, always check first to ensure that it has been received, inspected and installed in

accordance with the instructions herein. Rectify any discrepancies before proceeding further.

Check the compressor pump oil level by looking at the sight glass. The oil level should be at the top of the red circle on

the oil sight glass. Add oil, if required, through the oil fill cap and only when the unit is not operating. Do not overfill with

oil. Refer to the Maintenance and Repair section for recommended oil specifications. Check that the outlet valve, if fitted,

is closed. Any connected air hose(s) and/or distribution pipe(s) should not be open to the atmosphere. This is to prevent

any injuries from “hose whip” and/or high pressure air discharge and also to avoid unattended compressed air discharge

to the atmosphere. In the event that an air line is cut or broken, the air supply must be immediately closed off at the

compressor either by shutting the discharge outlet valve or switching off the compressor. Do not attempt to “catch” the

loose end of a discharging air hose.

Check that the tank drain valve is closed. Take care when discharging air from the tank, i.e. from the safety valve, the

drain valve or the air outlet, to ensure that it does not cause dirt, stones, metal swarf or other particles to be blown

around.

Any unusual noise or vibration likely indicates a problem with the compressor. Do not continue to operate the unit until

the source of the problem has been identified and corrected.

Duty Cycle

To maximize service life, the air compressor should be adequately sized for its given application. It should ideally

operate in a repeating run-stop or pump-unload cycle, with total compressor “pumping” time not exceeding 50% or 30

minutes in every hour on average. The elapsed time between the start and finish of any given pumping cycle (i.e. the

continuous duration that the electric motor operates) should not exceed 30 minutes. If the unit cannot supply the

compressed air demand without exceeding the above duty cycle limits, then either the demand should be reduced or the

compressor should be replaced with a larger unit having greater free air delivery.

The duty cycle limit is intended to protect the compressor pump valves and heads against stabilized high operating

temperatures that can cause premature pump failure.

Run in procedure

When starting for the first time leave the air compressor run for 10 minutes without load, leave the air cock completely

open. After 10 minutes check that the drain cock is closed and shut the main air cock. As tank pressure increases

check that the compressor stops automatically once maximum pressure is reached.

*Note: All compressors are delivered only after a successful testing period at the factory.

For the long life of your compressor it is recommended that you drain and replace the pump lubricant after 10 hours

of use, Drain the oil while it is still warm this will help remove any abrasive particles loosened from the initial run in

period. Replace pump oil with Scorpion Compressor oil AC-68.

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Optional Accessories (not standard equipment)

Air Dryer:-

A compressed Air Dryer is a device for removing water vapor from compressed air.

The process of compressing air concentrates water vapor from the atmosphere, which raises the dew point of the

compressed air relative to free atmospheric air and leads to condensation within pipes as the compressed air cools

downstream of the compressor.

Excessive water in the compressed air supply, either in the liquid or vapor form can cause a variety of operational

problems for users of compressed air. These include: corrosion of equipment, fouling of process lines and

contamination of jobs. Water vapor is removed from compressed air to prevent moisture entering tools and/or

interfering in sensitive industrial processes.

Refrigerated air dryers utilize a mechanical refrigeration system to cool the compressed air and condense water vapor.

Refrigerated air dryers cool the compressed air to a temperature of approximately 1.6 degree Celsius to 10 degrees

Celsius which results in a pressure dew point range of .5 degrees Celsius to 3.8 degrees Celsius. This range permits

the pressure dew point to fall within limits that are achievable with common refrigeration systems.

Pre and Post-Filters:

The Pre and Post- filters are designed with progressively finer filters to limit contamination by trapping the fine particle

matter and separating this matter from the air stream.

The Pre-Filter has a 5 micron filter that will trap most of the bigger contaminates that pass from the compressor.

The Post-filter has a 0.01 micron filter and is designed to remove any finer contaminates that the Air Dryer may have not

been able to remove.

Filter/Regulator

The filter/regulator is a pneumatic device which is comprised of a pressure regulator, a 25 micron filter and a water trap.

The regulator allows the operator to adjust the output pressure to suit the air tool that is being used.

It is suggested with this type of setup to have the filter/regulator mounted near to where the air tool is going to be used,

do not mount a filter regulator at the compressor as this will restrict air flow to the whole building system typically the filter

regulator is fitted where the piping changes to a flexible air line.

Table 4 shows the suggested Pre-Filter, Air Dryer, Post Filter and Filter/Regulator combination that can be used for each

particular Compressor.

Table 4

Model Pre-Filter Air Dryer Post-Filter Filter/Regulator

XRS25 JF-C-001 LD05SHA JF-A-001 SFR-404 XRS35 JF-C-002 LD10SHA JF-A-002 SFR-404 XRS50 JF-C-002 LD10SHA JF-A-002 SFR-404

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Chapter 3 Maintenance of the air compressor

WHEN DOING MAINTENANCE, YOU MAY BE EXPOSED TO ELECTRICITY, HOT SURFACES, HIGH

PRESSURE AIR, MOVING PARTS, OR FIRE WHICH MAY RESULT IN INJURY OR DEATH. BEFORE

PERFORMING ANY MAINTENANCE OR REPAIR, DISCONNECT ANY POWER SOURCE; LET THE

COMPRESSOR AND MOTOR COOL DOWN COMPLETELY. DRAIN ALL AIR PRESSURE FROM THE

TANK. CONTACT A SPECIALIZED SERVICE TECHNICIAN FOR ALL ELECTRICAL REPAIRS.

Before performing any maintenance or repair work on the compressor, switch off the unit, tag and lock out the power

supply, and carefully release all air pressure from the receiver tank, air hoses and/or air piping. Use only genuine spare

parts for maintenance and repair of the compressor to ensure its safe and reliable operation. The maintenance schedule

shown has been developed for typical industrial applications in clean indoor environments. The service intervals should

be shortened in harsher working conditions. Regular preventative maintenance is essential for the safety, reliability and

performance of the compressor and will add years to its useful life.

3.1 Regular maintenance schedule

Keep your air compressor in good condition, regular inspection and maintenance is very important.

Service period regular Item

Every day

After 10 Hrs Every month Every 6 months Every year

Check the oil level �

Drain tank condensation �

Check V belts Tension � 1st time � 2nd and thereafter

Test Safety Valve �

Clean air intake filter (Service more frequently

when used in dusty conditions)

� � Replace filter

element

Change pump oil � 1st time � 2nd and thereafter �

Check bolt tensions � 1st time

General cleaning of the compressor, check for air and oil leaks

� �

“�” The chart above indicates which checks to make and when to make them.

15

Check for any loose fasteners after 10 hours of operation

• Check that all nuts and bolts are properly tight

• Drain and replace the pump lubricant Replace pump oil with Scorpion compressor oil.

(this will remove abrasive particles, from initial run in period)

After 10Hrs of use

Air filter maintenance

Remove the outer cover to access the filter element

Paper air filter elements, can be cleaned by gently blowing with compressed air (20psi) from the inside out.

Air filter maintenance

Air filter maintenance will be increased when the compressor is used in dusty conditions. If it cannot be blown clean or is otherwise torn or damaged, the filter element must be replaced. Replace the filter every 12 months. Do not operate the compressor without an air filter. Foam air filter elements should be washed in warm soapy water, allow to dry, then re-oiled before use.

16

Check belt tension Correct belt tension is important if the belt is too tight it will cause the motor to overheat and increase electricity consumption. If the belt is too loose it may slip easily, whip and break. The drive guard must first be removed before V-belt tension can be checked or adjusted, hang a weight of about 3kg at the mid point of the belt. Deflection should be about 10mm. If tension adjustment is necessary, loosen the four fasteners holding the motor to the baseplate. Then either move the

motor away from or closer to the pump to increase or decrease V-belt tension, respectively, and retighten the

hold-down fasteners. Always use a straight edge to check that the motor

and pump pulleys are properly aligned and the V-belt(s) runs straight. Do not over tension the V-belt(s). Always

refit the drive guard before operating the compressor.

Correct pulley alignment is extremely important!

Cleaning

Switch off the air compressor and use light air pressure to blow dust and foreign matter off the compressor pump, motor,

piping and air receiver tank. Oil and grease marks should be cleaned off using mild household surface cleaner and a

soft rag. Do not use abrasive cleaners or strong solvents that can damage the compressor’s paint finish.

Air Receiver Tank

To drain condensation from the air receiver tank, slowly open the drain valve and allow the condensation to discharge.

Do not pollute the environment by improper or illegal disposal of the condensation that may contain lubricating oil and/or

other contaminants. Use extreme caution when opening the drain valve if the air receiver tank is pressurized.

Thumbscrew drain cocks should not be opened more than one full turn.

Certified external and internal inspections of the air receiver tank should be carried out by a licensed in-service inspector

at intervals of no less than two and four years, respectively, in accordance with Australian and New Zealand Standard

AS/NZS 3788:2001 or as otherwise specified by your applicable Occupational or Workplace Health and Safety

Regulations.

Do not attempt to repair or modify an air receiver tank. Welding, drilling or any other modification will weaken the tank

and may result in damage from rupture or explosion. Always replace worn, cracked, corroded or damaged tanks.

Safety Valve

Regularly check the safety valve to verify that it’s operating freely. While the air receiver tank is pressurized to at

least 120 psi, pull the ring on the safety valve and allow it to snap back to its normal position. If air leaks out

after the ring has been released, or the valve is stuck and cannot be actuated by pulling the ring, the safety

valve is faulty and must be replaced before operating the compressor.

Take care when testing the safety valve as compressed air will discharge from the valve with high velocity. Do not

tamper with the safety valve. It is designed to automatically release air if the tank pressure exceeds a preset maximum.

17

Air Tightness

While the air receiver tank is pressurized to at least 120 psi and the compressor is switched off, listen for any audible air

leaks. Squirt soapy water around any suspect joint and watch for bubbles indicating a leak. De-pressurize the air

receiver tank carefully and all connected air hoses and/or air piping before commencing any repairs.

Disassemble the leaking joint and clean off all traces of thread tape or sealant using a wire brush. Apply PTFE thread

tape or Loctite™ 243 liquid sealant to the male threaded connection before reassembling and tightening the joint. Allow

approximately 30 minutes for the liquid sealant to cure, if used. Re-pressurize the air receiver tank and check that the

air leak has been rectified before putting the unit back into normal operation.

Lubricating Oil

Maintain the oil level at the top of the red circle on the oil sight glass fitted to the compressor pump.

Remove the oil fill cap to add oil only when the compressor is switched off.

Use premium quality engine oil with an API Service Classification of at least CG or SH, or alternatively use specialized

air compressor oil meeting DIN 51506 specification. Select an oil of monograde or multigrade viscosity that is appropriate

for the ambient temperature in which the compressor will be operating.

The compressor pump has been filled at the factory with SAE 15W-40 mineral based engine oil that is suitable for

ambient temperatures from −15°C (5°F) to over 40°C (104°F). Mineral based, semisynthetic or fully synthetic oils may

be used, but different types of oils should not be mixed together. Regular oil changes in accordance with the

recommended maintenance schedule are crucial to the service life of the compressor pump.

To change the oil, remove the oil fill cap and then remove the oil drain plug. Another way is to simply evacuate the oil

through the oil fill hole by inserting a suction probe. Oil flows easier if the pump is warm, but do not touch the oil in case it

is hot. Reinstall the oil drain plug tightly before adding the new oil and then finally screw the oil fill cap back in place.

If the oil changes to a white colour, this indicates water contamination. If it changes to a dark colour, this typically

indicates compressor overheating. Change the oil immediately in either case. Do not pollute the environment by

improper or illegal disposal of waste oil. New or rebuilt compressor pumps will discharge higher than normal amounts of

oil until the piston rings are seated in, which can take approximately 100 operating hours. Some oil may also

concurrently accumulate at the crankcase breather openings and this too will diminish with run time.

TROUBLESHOOTING

Before performing any inspection, test or repair work on the compressor, switch off the unit, tag and lock out the power

supply, and carefully release all air pressure from the receiver tank, air hoses and/or air piping.

Please refer to the troubleshooting guide shown in Table 5 for assistance with diagnosing and repairing any problem that

might occur with your air compressor. Whilst many of the tasks can be undertaken by a mechanically proficient person

with access to proper tools, all electrical work must by undertaken by a licensed electrician.

It is recommended for your convenience and expedience that the troubleshooting guide is consulted prior to contacting

advice.

Use only genuine spare parts for maintenance and repair of the compressor to ensure its safe and reliable operation.

For best results, the following repair procedures should always be observed:

Use only genuine spare parts for maintenance and repair of the compressor to ensure its safe and reliable operation.

• Use new gaskets, seals and O-rings during reassembly.

• Use PTFE thread tape or Loctite™ sealant on threaded joints subject to pressure.

• Use Loctite™ retaining compound when fitting engine or motor pulleys onto their drive shafts.

18

Symptom Possible Cause Corrective Action Motor will not start, runs slowly or repeatedly trips out overload protection.

1. Pressure switch not turned on.

2. Air receiver tank pressure above cut-in pressure.

3. No voltage at the pressure switch.

4. No voltage at the electric motor, (faulty pressure switch or DOL starter)

5. No voltage on one or two phases of 415v supply.

6. Low supply voltage.

7. Thermal overload relay in DOL starter tripped.

8. Faulty pressure switch unloader valve, (nil or restricted unloading air flow.

9. Nil or restricted discharge air flow through non-return valve.

10. Damaged motor cowl and/or fan, other motor faults.

11. V-belts too tight or misaligned.

12. Compressor pump partially or totally seized.

1. Turn on pressure switch.

2. Nil (no fault). Unit will start when pressure drops.

3. Check electricity supply including all fuses, circuit breakers, switches and wiring.

4. Repair or replace pressure switch or DOL starter.

5. Check voltage on all three phases of 415v supply.

6. Check no load and full load supply voltage. Upgrade power supply circuit if required. Disconnect any other appliances on the same supply circuit.

7. Allow motor to cool down and manually reset overload relay (located inside the DOL starter).

8. Replace unloader valve or complete pressure switch.

9. Repair or replace non-return valve.

10. Replace cowl and/or fan, replace motor.

11. Adjusts belts to proper

tension and alignment. 12. Repair or replace

compressor pump.

Compressor pump does not come up to speed.

1. Loose motor pulley, loose compressor flywheel or loose/worn V-belts.

2. Low supply voltage.

3. Damaged or worn.

4. Compressor pump partially seized.

1. Tighten or replace pulleys as required, check alignment and adjust V-belt tension.

2. Check no load and full load supply voltage. Upgrade power supply circuit if required. Disconnect any other appliances on the same supply circuit.

3. Replace compressor pump valves and or blown head gaskets.

4. Repair or replace compressor pump.

19

Excessive noise (including knocking and rattling) or vibration.

1. Loose motor pulley, loose compressor pulley, V-belts too tight or misaligned.

2. Low oil level. 3. Pistons hitting cylinder

heads.

4. Damaged or worn crankshaft bearings, crankshaft, con-rods, piston pins, pistons, cylinders and /or valves.

5. Faulty non-return valve.

6. Loose fasteners.


2. Add oil. 3. Remove cylinder heads and

check for foreign matter on top of pistons.

4. Replace components or entire pump.


6. Check and tighten fasteners (including foot mounts).

Slow pressure rise or unable to reach cut-out pressure.

1. Air demand exceeds compressor pump capacity.

2. Air leaks.

3. Blocked or dirty inlet air filters.

4. Loose motor pulley, loose compressor flywheel pulley or loose/worn V-belts.

5. Head unloaders not fully retracting (usually indicated by air blowing out from air filter inlets).

6. Damaged or worn compressor pump valves and/or blown cylinder head gaskets.

7. Damaged or worn piston rings, pistons and/or cylinders.


1. Reduce air demand or use larger or additional compressor(s).

2. Tighten or refit or replace leaking connections or components.

3. Clean or replace air filter elements.


5. Repair or replace head unloaders.

6. Replace compressor pump valves and/or cylinder head gaskets.

7. Replace components or entire compressor pump.


Compressor pump runs excessively hot (possibly melts air filter enclosures).

1. Incorrect direction of rotation.

2. Ambient temperature too high or insufficient ventilation.

3. Low oil level. 4. Excessive duty cycle.

5. Damaged or worn compressor pump valves and/or blown cylinder head gaskets.

1. Check compressor pulley turns in correct direction Change electric motor wiring connections if incorrect.

2. Reduce ambient and/or improve ventilation (e.g. move further away from walls or other equipment).

3. Add oil. 4. Reduce air demand or use

larger or additional compressor(s).

5. Replace compressor pump valves and/or cylinder head gaskets.

Excessive cycling between pumping mode and off mode.

1. Excessive duty cycle.

2. Air leaks.

3. Excessive condensation in air receiver tank.

1. Reduce air demand or use larger or additional compressor(s).

2. Tighten, refit or replace leaking connections or components.

3. Drain air receiver tank more regularly.

20

Excessive oil in discharge air. 1. Blocked or dirty inlet air filters.

2. Overfilled with oil. 3. Low oil viscosity.

4. Excessive duty cycle.

5. Blocked or damaged crankcase breather.

6. Damaged or worn intake valves, piston rings, pistons and/or cylinders.

1. Clean or replace air filter elements.

2. Drain oil down to high level mark.

3. Replace with correct oil. 4. Reduce air demand or use

larger or additional compressor(s).

5. Clean or replace crankcase breather.

6. Replace components or entire compressor pump.

Water in discharge air. 1. No fault, this is normal operation. Condensation quantity will increase with duty cycle and humidity.

1. Install dryer and/or filter in discharge line. Install automatic tank drain valve or manually drain air tank more often. Revise distribution piping system to ensure proper condensation drainage.

Compressor does not switch off and safety valve discharges.

1. Faulty pressure switch. 2. Faulty safety valve. Note:

use tank pressure gauge to help diagnose fault.

1. Replace pressure switch. 2. Replace safety valve.

Low suction or air blowing out at air filter inlets during pumping mode.

1. Damaged or worn compressor pump inlet valves and/or blown cylinder head gaskets.

1. Replace compressor pump inlet valves and/or cylinder head gaskets.

No Short discharge of air from the pressure switch after reaching cut-out pressure or being manually switched off.

1. Faulty unloader valve in pressure switch.

2. Blocked or damaged unloading line.

3. Blocked or faulty non-return valve.


2. Clean or replace unloading line.

3. Clean, repair or replace non-return valve.

Short initial discharge of air from 240v pressure switch during pumping mode after starting with nil or low pressure in air receiver tank.

1. Correct function of the “soft start” pressure switch unloading valve to reduce motor starting current.

1. Nil (no fault)

Continuous discharge of air from the pressure switch after reaching cut-out pressure or being manually switched off.



Continuous discharge of air from pressure switch during pumping mode.

1. Faulty unloader valve in pressure switch.


Air receiver tank does not hold pressure when compressor is off and discharge outlet valve is closed.


2. Air leaks.


2. Tighten, refit or replace leaking connections or components.

External oil discharge from compressor pump.

1. Oil leaks 1. Tighten, refit or replace leaking connections or components.

Oil appears “milky” in sight glass. 1. Water contamination in oil. 1. Replace oil and move compressor to less damp or humid location.

Oil appears black in sight glass. 1. Graphite carry-over from cast iron material (initial oil fill only).

2. Oil dirty and/or overheated (initial or subsequent oil fill).

1. Replace oil.

2. Replace oil and check for compressor pump overheating.

21

To obtain local service agent locations: http://www.austechindustries.com.au/html/service.html

or email: [email protected]

TRANSPORT

Always de-pressurize the air receiver tank before transporting the air compressor. Always keep the compressor level to

prevent oil spillage. Ensure that adequate lifting equipment is available for moving and loading the compressor. Lifting

equipment, slings, etc. must be properly rated for the weight of the compressor. Take care when attaching load

restraining devices to ensure that the compressor does not tip over during transport, especially because of its high centre

of gravity. Check with the carrier whether lubricating oil must be drained out prior to transport. If so, ensure that the

party receiving the compressor is notified accordingly. Keep the compressor covered during transport to prevent the

ingress of dust and debris.

STORAGE

Always de-pressurize and drain the air receiver tank before storing the air compressor. Always keep the compressor

level to prevent oil spillage. Store the compressor in a cool, dry and shaded place and keep it covered to prevent the

ingress of dust and debris. If storing the compressor for a long period, the following additional preparations should be

made:

Austech Industries Pty Ltd A.B.N. 19 010 548 464

23 Iris Place, Acacia Ridge, 4110

PO Box 715

Archerfield Qld 4108

Brisbane Australia

T: (07) 3723 1500

F: (07) 3723 1555

Effective 1st Day of December 2013

Limited Warranty Policy

This Limited Warranty applies only to new products* distributed by Austech Industries Pty Ltd (“Austech Industries”). It is a condition of this Limited Warranty Policy that the purchaser read the owner’s manual for the product and only use the product to the extent or for the purposes stated therein. The purchaser must also ensure that all servicing requirements are completed as listed in the owner’s manual (said servicing is at the owner’s expense). We recommend that all servicing is completed by an authorised service agent and that records of said servicing are retained by the purchaser as proof in the event of a warranty claim. Whilst the owner’s manual, packaging, and/or other documentation supplied with Austech Industries’ products may provide details in respect of a Limited Warranty, the terms set out herein supersede these matters, and this Limited Warranty applies in their place. This warranty is no less advantageous than otherwise described in such other documentation. Austech Industries agrees, subject to the terms and conditions specified below, to repair or replace at Austech Industries’ cost, the product purchased by you when the product does not perform in accordance with its specifications during the limited warranty period, due to any fault in manufacturing, materials and/or workmanship. Austech Industries is not liable to repair or replace products that the purchaser uses in a manner that is inconsistent with the owner’s manual or in the circumstances set out in paragraphs 1.1 – 1.7 below. The benefits to the purchaser under this warranty are in addition to other rights and remedies under the Competition and Consumer Act 2010 (Cth). The limited warranty period, within which a defect in the product must appear, commences from the date of purchase and ceases on expiration of the specified term below.

Period & Scope of coverage: a) 36 month or 3 year coverage: The compressor pump is warranted to the original purchaser to be free from defects in

materials and or workmanship for a period of 36 Months or 3 years from the original purchase date. This does not include serviceable items such as, but not limited to – Filters, valve plates, non return valves, delivery tubes, gaskets, seals, sight glass, bearings or lubricating oil.

b) 12 month or 1 year coverage: The following items are warranted to the original purchaser to be free from defects in materials and or workmanship for a period of 12 months or 1 year from the original purchase date: Electric Motor, Pressure switch, Pressure regulator and Pressure vessel.

c) 3 month or 90 day coverage: Serviceable and or ancillary items are warranted to the original purchaser to be free from defects in materials and or workmanship for a period of 90 days or 3 months from the original purchase date. Items such as but not limited to: Air Hoses, Air fittings, Air filters, Wheels, Capacitors, Finish, Gauges and Fasteners.

The purchaser’s attention is drawn to the following � To the extent permitted by law and subject to this Limited Warranty, and as part of the terms of the sale of the equipment or

part thereof: Austech Industries shall not be liable for any form of loss, damage, cost, injury or harm of any kind (whether direct, indirect, special or consequential) howsoever arising from the use or supply of the equipment to the purchaser.

Exclusions to Limited Warranty Policy This Limited Warranty will not apply where the equipment or any part thereof: 1.1 1.2 1.3 1.4

1.5 1.6 1.7

Fails due to an accident (including liquid spillage), abuse, misuse, neglect or normal wear and tear; Has been used in a manner other than for which it was originally designed; Has been tampered with or is otherwise than as supplied by Austech Industries; Where any damage, malfunction or other failure of the equipment or any part thereof resulted directly or indirectly from unauthorized persons, adjusting or failing to adjust any part requiring normal maintenance and service (examples include adjustment of tappets, air filter maintenance, lubrication and tightening of screws nuts and bolts); Malfunctions due to the use of defective or incompatible accessories; Is damaged by lightning or thunderstorm activity; or Has been transported to a country where no authorised Service Agents exist.

Claiming warranty This Limited Warranty may be claimed on in the following manner: 2.1

2.2

2.3

In order to make a claim under this Limited Warranty, the purchaser must deliver the equipment or any part thereof to an Austech Industries authorised repair agent and pay all costs of transportation and all costs incidental to making a claim under this Limited Warranty. The purchaser must first contact Austech Industries (contact details described above) and request the delivery address of an Austech Industries authorised repair agent. The purchaser must deliver to the repair agent written reasons why the purchaser considers that the purchaser has a claim under this Limited Warranty and must provide all necessary details, including:

• The place, date and from whom the unit or part was purchased. • The unit or part involved, Model and Serial Number. • The defect, malfunction or failure in respect of which the claim is being made. • Proof of service of the unit or part (if applicable) • Proof of purchase in respect of the unit or part.

If the Limited Warranty claim is valid, the repair agent will carry out repairs and return the product at no charge to the purchaser. These repairs are limited to the Limited Warranty fault identified and as such will not include any other faults due to misuse, abuse, failure to maintain, fair wear and tear or the replacement of serviceable items such as oil, spark plugs, air filters, fuel etc.

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

* SP, Scorpion, Fini, & SRT are all brand names of products distributed by Austech Industries

Note # Units which are failing to perform in accordance with specifications due to non-warrantable causes will be subject to freight, repair and or quote charges.

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