installation/operation manual
Contents
1. Replace Clean and check for valve damage Replace Tighten screws Replace unit Replace bearings Replace silencer To insure you received the correct parts you need to provide the model number of the unit and the serial number along with the part number as shown below duing winnoeg pue JOossaidwoy uoj sig Bulys0y S9H9S 09 dy 8 Ody JODUd IS 19409 yorg Bury O qnfuyo uuog Jaddij4 aaresoddy zzgoz9 Buieeg 4004 Jeqqny Joyoedeg 8 GN M S yoyoeig zz9009 Bue g zz9009 Bune g Jayga Buuds SL SIN M S dwejo Burxi4 M S MaS J3A09 pe H Bury O NLA BIL NLA Jadde 4 NRUMOG di S paxiy ALA S YN M S Bury O 43pu149 JapulAd OL SIW MaS 3 e q punoy dng uojsid 10 8 S 10 0H Buisnoy POY UO sIq 91 U9999 uey Buljoo9 J A09 Uey Buljoop SEO veo 0 zeo LeO 0 0 620 820 2c0 920 Sco tzo ezo zzo LZO ozo 610 840 440 910 SLO YO L0 ZO LLO O10 600 800 200 900 Soo v00 00 200 400 23 To insure you received the correct parts you need to provide the model number of the unit and the serial number along with the part numbers as shown below dund wnnoeA pue 10ssaidwoy uo jsig bulyo0y SOMOS 00Z dY 08l du Ovl dd OZL dY 06 dy JE9UB IS 13409 yeg 6ury O qnfugo uuog saddij4 avyesaddn Zz 0z9 une g yoo Jaqqny Joyloedeg 8 GW M S yjeyoelg 229009 une g 2z9009 une g Jeyge Buds GL SW Meas0S dwe 9 6buxi4 MaS M S JOAOD pe H Bu2. remove it from the housing Remove the connecting rod and piston from the housing Note Do not damage the piston cup 4 when removing the connecting rod assembly from the pump housing If the cup is damaged it must be replaced FIGURE 8 Rebuilding Connecting Rod Assemblies If you are rebuilding the connecting rod assembly using component parts follow the procedure below When replacing the piston cup 4 be sure to replace the sleeve 1 at the same time Please the connecting rod in a fixture before attempting to remove the retainer screw If necessary heat will help to remove the piston cup 1 Remove the retainer screw 2 from the cup retainer 2 Remove the retainer 3 from the connecting rod 3 Remove the cup 4 and discard 4 Place t he new piston cup 4 on the connecting rod 5 Place the new piston cup retainer 3 on the cup connection making sure the boss of the retainer is seated in the pilot of the piston rod 6 Insert the retainer screw 2 into the connecting rod 5 FIGURE 9 and tighten the screw with a torque wrench to 26 lbs 14 Assembly Of The Connecting Rod To The Pump 1 Put cylinder sleeve into the trough of housing keeper and make connecting rod vertical Note Connecting rod screw to face the housing FIGURE 10 Assembly Of The Connecting Rod To The Pump cont d 2 Replace the eccentric onto the shaft and insert bearing into connecting rod bearing housing Rotate
3. facing the valve plate and oriented as shown in Figure 3 7 Line up the screw holes in all of the valve components and fix the screw on the valve plate 8 Make sure the flapper valve is centered over the port of the valve plate and that all of the other components line up with the flapper valve 9 Tighten the flapper valve screw to 11 5 lbs using a torque wrench with a screw attachment CAUTION Do not over tighten the flapper valve screw or it will shear off in the valve plate FIGURE 3 Replacing A Flapper Valve On The Bottom Side Of The Valve Plate 1 To replace a flapper valve on the bottom side of the valve plate side facing the pump housing remove the flapper valve screw 1 lift off the valve keeper strip 2 2 Clean any debris with a soft damp cloth Turn the pump housing head upside down and place the valve plate on the pump head and orient it shown in Figure 4 3 Orient a flapper valve 3 over Port 2 Observe the location of the location of the notches at the end of the flapper valve 4 Place a valve keeper strip 4 over the flapper valve observing that the radius of the valve plate and oriented as shown in Figure 4 5 Line up the screw holes in all of the valve components and fix them upon the flapper valve screw by screws 6 Make sure the flapper valve is centered over the Port and that the valve keeper strip lines up with the flapper valve 7 Tighten the flapper valve screw to 12 4 lbs
4. with a torque wrench FIGURE 4 Servicing Connecting Rod and Eccentric Assemblies Note Refer to the Preventative Maintenance and Troubleshooting guide in this manual to determine whether a compete connecting rod assembly or it s component parts or an eccentric needs to be serviced Components Required 1 Connecting rod assembly piston cups and sleeves 2 Valve plate gasket O rings 3 Head gasket O rings if defective Removing The Connecting Rod and Eccentric Assembly Note Only remove one connecting rod assembly at a time 1 Carefully remove the cooling fan by pulling it straight off the pump shaft Do not pull the motor fan blades FIGURE 5 Cooling Fans Removing The Connecting Rod And Eccentric Assemblies cont d 2 Turn the motor shaft to align the eccentric setscrew the connecting rod screw separately and with the hole of the housing See Figure 6 for location of access hole FIGURE 6 Eccentric screw access hole Eccentric 10 Removing The Connecting Rod And Eccentric Assemblies cont d 3 Slide the eccentric bearing assembly straight off the shaft FIGURE 7 11 Removing The Connecting Rod And Eccentric Assemblies cont d 4 Slide and rotate the connecting rod remove it from the housing Remove the connecting rod and piston from the housing FIGURE 8 12 Removing The Connecting Rod And Eccentric Assemblies cont d 4 Slide and rotate the connecting rod
5. Mounting of unit The unit should be mounted on an adequate mounting base using the rubber foot pads to isolate any vibration being transmitted to the mounting surface ELECTRICAL CONNECTION The power supply must be the same voltage and frequency as listed on the nameplate The motor is a single phase capacitor type and it has one cable connection Connect the incoming power two conductors to the motor terminals and connect the earth ground wire to the earth terminal The motor must be protected by a motor starter with a thermal overload A circuit breaker of adequate capacity based on the motor nameplate amperage must be used A thermal protector is wound into the motor winding that can be use for additional temperature protection of the motor A DANGER The motor must always be disconnected from the power supply prior to performing any maintenance on the unit The electrical disconnect should have a lock out feature to prevent an accidental start up while the unit is being serviced MAINTENANCE The points mentioned in this section are based upon the pump being applied in what can be considered a normal or standard installation If the unit is installed or operated in any excessive condition eg dirty environ ment high temperature and so forth the needs to be maintained frequently Cleaning The external surface of the pump should be cleaned of any debris to allow for effective cooling of the unit Annual Maintenance The sile
6. OPERATING SERVICE MAINTENANCE MANUAL ALL STAR ROCKING PISTON COMPRESSOR AND VACUUM PUMP Registered by one or more of these standards agency j CE D RoHS SAX CE D CEFE Compliant c US Read through carefully and understand these instructions before use All Star Products Tel 901 755 9613 www all star usa com Contact your supplier or Informati Have the pump model and serial numbers when ordering parts or when contacting All Star or your supplier e SuUa Manual Read First Read the Safety Rules below before m working on the pump Saty Rules A DANGER ndicates an imminently hazardous situation which if not avoided will result in death or serious injury 1 Indicates a potentially hazardous WARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous A CAUTION situation which if not avoided may result in minor or moderate injury NOTE This Service Manual is intended for use ONLY by a service center with properly trained and experienced repair personnel The instructions and warnings contained herein presume existing familiarity with the design and function of this type of product and their components The information contained in this manual is subject to change without prior notice The manufacturer should be contacted prior performance any maintenance to determine if any changes have been made to the information contained herein
7. cking piston pump is designed for continuous duty The cooling fins on the unit should remain open to allow free air circulation and the unit must be locate at least 150mm 6 inches away from any surface Do not allow hot air to circulate on or about the unit STORAGE If the unit is placed into storage for a period of time greater than one 1 year it should be stored in a dust free area subject to a maximum temperature of 40 Deg C 104 Deg F and where it will not be subject to vibration If stored for longer than one 1 year the bearings should be replaced prior to start up Mechanical Connections If the unit is to be connected to a network a flexible hose should be installed to eliminate mini vibrations from reverberating in the system piping The connections on the unit are either 25 or 375 NPT threads For vacuum applications piping connections to the exhaust orifice can be made to direct the heated discharge air to an exhaust outlet This piping should not be smaller than the connection on the unit If a smaller discharge pipe size is used this can result in reducing the pump speed and could overload the motor If multiple units are installed on a network system the exhaust pipe must equal or be greater than the coss section of the total diameter of all of the units in the system A drain valve at the lowest point of the exhaust line must be installed to prevent any condensation from draining back into the unit s
8. closure 3 Remove all screws 1 that faster the head 2 to the pump housing 4 Carefully separate the head from pump body Carefully separate the valve plate assemblies 4 from the heads Remove the head gasket O rings and replace Turn the valve plates over and replace the valve plate gasket O rings NON FIGURE 1 Removing Flapper Valves Note It is recommended that you replace one flapper valve at a time This will help to simplify the repair process and correctly orient the flapper valves in the valve plate 1 If you are replacing a flapper valve on the topside of he valve plate the side facing the head remove the flapper valve screw 1 Lift off the valve keeper strip 2 lift off the strengthen valve 3 and lift off the existing flapper valve 4 2 Remove any debris from the valve plate with water free alcohol soap or other detergent should not be used due to the potential for corrosion from the soap 3 Please the valve plate on the compressor housing and orient it as illustrated Make sure the O ring head gasket is towards the cylinder Note the orientation of the valve ports 4 Orient a new flapper valve 4 over Port 1 Observe the location of the end of the flapper valve continued on next page FIGURE 2 Removing Flapper Valves continued 5 Place a valve restraint 3 over the flapper valve 6 Place a valve keeper strip 4 over the valve restraint observing that the restraint s radium is
9. e supply Bent motor shaft Worn bearings Burned out fuses Motor starter thermal protector Piston jammed High voltage supply Low voltage supply Broken fan Bent motor shaft Damaged capacitor Overload condition High ambient poor ventilation Starter OL set incorrectly Installation Leak Wrong direction of rotation Piston joint not working Defective blade valve Dirty air filter Pump undersized for load Loose head screws Damaged valves Worn cup Damaged gaskets Debris in valves Damaged valves Debris in valves Worn cup Loose head screws Bent motor shaft Worn bearings Silencer 22 Corrective Action Insure rated voltage is applied by changing power supply Replace entire unit Replace bearings Check incoming power and use only slow blow fuses Check to see if thermal protector has tripped Dismantle cylinder head and repair Insure rated voltage is applied by changing power supply Same as high voltage Replace fan Replace entire unit Replace capacitor Reduce pressure vacuum to bring motor amps down to nameplate rating Insure the motor ambient does not exceed 40 Deg C Verify starter OL is set correctly Check fuse size Reduce pump load Clean air filter amp element Correct any leakage Change electrical connection Replace Replace Clean and or replace Replace with larger unit Tighten screws Replace valves Replace cup Replace gaskets Clean and check for valve damage
10. eccentric to line up set screw with access hole in bottom of housing Rotate main shaft and let shaft flat and eccentric screen hole line up vertically Tighten screw to with a torque wrench to 35 Ibs 3 Rotate shaft with connecting rod moving up and down The connecting rod should move freely with out any obstacle or restriction Use Allen head wrench to tighten rod screws FIGURE 11 Set screw access hole Assembling The Pump 1 After the connecting rod assembly and the eccentric are correctly assembled assembly of the valve plates and O ring should be assembled next CAUTION To prevent damage to the pump never apply any sealant or lubricant to the O rings FIGURE 12 Bottom of valve plate O ring grove 17 Assembling The Pump cont d 2 Insert the valve plate gasket O ring into the O ring groove located on the bottom of the valve plate 3 Position the pump housing as shown in Figure 13 Note the orientation of the power leads NOTE Insure the connecting rod sleeves are seated against the pump housing FIGURE 13 18 Assembling The Pump cont d 4 Note the orientation of the valve plate assemblies Place them on the pump housing as shown in Figure 14 FIGURE 14 Valve Plate Pump Housing 19 Assembling The Pump cont d 5 Insert two new head gasket O rings into the groove located on the bottom of the head NOTE Insure the valve plate is properly engaged
11. ncer should be dismantled and cleaned or replaced if necessary The filter cartridge should be replaced The All Star rocking piston pump has a designed service life of approximately 10 000 hours Once the pump reaches this point or approximately two 2 years the cylinder head and casing seal needs to be replaced This period is merely a suggestion and is dependent upon the duty cycle and environmental conditions 10 000 Hour or Two Year Maintenance In performing this maintenance it is recommended to perform the following a Replace the connecting rods or piston cups and sleeves b Replace the flapper valves c Replace the head O ring head gasket d Replace the valve plate O rings Required tools for blower maintenance a Torque wrench required for head screws connecting rod flapper valve screws and pipe plugs Allen head wrench with attachments for torque wrench Cross head attachment for torque wrench Screw driver Soft clean cloth b Sra a c d d Servicing the Head Valve Plate Assembly and Connecting Rod and Bearing Assembly Figure 1 Note The head would only need to be replaced if it is visibly damaged Parts Required Head if damaged Head gasket Valve plate O ring Complete valve plate assembly or individual flapper valves Flapper valve screw s if replacing individual valve s Removing the Head 1 Disconnect the power to the motor 3 Disconnect all airlines and remove the unit from any en
12. prior to performing any service or maintenance work Connection Diagram Note The intake suction and the discharge piping should not be smaller than the connections in the unit The piping can be a larger diameter If the unit is used in a network arrangement with other pumps or compressors the diameter of the piping should not be less than the total surface area of the total number of pumps connected in the network VACUUM PUMP CONNECTION Capacitor Discharge Connection S lt om O gt _ Inlet Suction amp Filter COMPRESSOR CONNECTION Capacitor lt a Om 9 Discharge 9 OSO O Inlet Filter COMMISSIONING A DANGER This pump and compressor is to be used for pumping non aggressive gasses air containing no more that 22 oxygen This unit is not approved for nor should be used for explosive or toxic gasses warning RISK OF BURNS DO NOT TOUCH 1 0 2 0 The surface temperature of the machine can reach 80 Deg C 175 Deg F when operating at full load conditions Wait until the unit cools down prior to performing service work The unit must be installed in a well ventilated dust free room The maximum ambient if 40 Deg C 104 Deg F Intake and discharge air should be piped to limit ambient air temperature as noted above The ro
13. r maintenance or improper storage Neglect or accidents are also excluded from this Limited Warranty This Limited Warranty is effective provided 1 the purchaser immediately notified All Star Products in writing of the alleged defect after it becomes known to the purchaser and 2 no alterations repairs or services have been performed by the Purchaser or third parties on the product without written approval of an officer of All Star Products 3 a properly sized air filter has been installed This Limited Warranty does not cover misuse misapplication abuse neglect or other causes of failure beyond the All Star Products control The product should not be disassembled or a repair attempted Any attempt to disassemble or repair to correct a problem by the customer or their agent will void the Limited warranty A disassembled unit will not be considered as a warranted failure under any circumstances For more information visit http www all star usa com All Star Products Inc Main Office amp National Warehouse 2095 Exeter Rd Ste 80 324 Memphis TN 38138 Tel 800 431 8258 Tel 901 755 9613 Fax 901 758 0816 marc all star usa com
14. ry O ane eld LA Js ddej4 4UMOQ dins p X 4 LA S YN M S Bury o 1 pu1 K9 J pul o OL SW MaS ejd punoy dng uojsid Jo e1S JO OY Bulsnoy Poy UO s q 91JU999F ue 4 Buljoop JOA09 Uey Buljoog 24 All Star products are high quality engineered and manufactured blowers They are designed to meet international standards and have received approvals and recognition from one or more of the following Registered by one or more of these standards agency CE D CERE RoHS Adus LIMITED WARRANTY All Star Products warrants all of its products against defects in material and workmanship for a period of one 1 year from the date the product was placed in service within a maximum of eighteen 18 months from the date of shipment whichever occurs first Purchaser is responsible for providing adequate and approved storage during the eighteen 18 month period Not withstanding the foregoing any equipment or components of the products not of All Star Products manufacture and or specified by the Purchaser is sold under only such warranty as the make thereof extends to All Star Products and All Star Products is able to enforce but such items are not warranted by All Star Products in anyway All Star Products is not responsible for product failures caused by the Purchaser or their customer misapplying the product operating the product beyond the published ratings and values misuse field alterations and changes lack of prope
15. to the housing locators NOTE Insure that the O rings are fully assembled in the grooves and that they are not pinched FIGURE 15 Bottom of the head O ring gasket 20 Assembling The Pump cont d 6 Place the head on the valve plate assemblies observing the position of the air intake and exhaust ports NOTE Make sure the head gasket O rings are not pinched 7 Insert the head screws and tighten each screw in the order as shown in Figure 16 until it is snug Used a torque wrench with a screw adapter to tighten each head screw to 31 lb setting A CAUTION To avoid property damage or personal injury always rotate the fan by HAND initially and prior to connecting the motor to a power supply Check for suction at the air inlet port by placing one finger over the port as you turn the fan You should feel a slight suction with each rotation of the fan If you don t feel suction or if you hear a thump as you turn the fan DO NOT CONNECT THE UNIT TO YOUR POWER SOURCE and review the assembly procedure to determine the problem FIGURE 16 Capacitor 21 Troubleshooting Guide Motor Does Not Start Motor Overheats Motor Starter Trips Low Pressure Low Flow Noisy Unit Possible Cause Low voltag
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