Stellar Industries Compressor V480 User's Manual
Contents
1. ITEM PART DESCRIPTION 1174 CASE V480 360 14 0052 PLATE MACHINED 5822 GASKET BEARING CARRIER VA80 015 15 0054 PLATE COVER GASKET SMALL 5821 BEARING CARRIER OIL PUMP V360 V480 16 22626 PLATE COVER C1164 BEARING CUP L44610 17 0485 CAP SCR 0 31 18X1 25 HHGR5 22834 V480 S 18 6031 SCREW 0 31 18X1 00 SHC 0856 BEARING CONE 8 19 6034 SCREW 0 31 18X1 00 SHC C0855 BEARING CONE 20 22209 PIN 0 19X 63 5820 OIL PUMP DRIVE SLEEVE V480 V360 200 21 C0055 OIL INTAKE PLUG 5817 ROLL PIN 0 19X 50 22 C5416 TUBE OIL INTAKE 38 X 3 00 0060 SPRING OIL PUMP 23 0058 INTAKE FILTER SCREEN 0059 PUMP TRANSFER BUSHING 24 C6273 SNAP RING PISTON PIN N5000 62 0050 PUMP 25 C4841 PLUG 0 38 SQ HD BLK C6275 PORT PLATE GASKET 26 23482 BEARING CARRIER V480 FT 480 360 05 a fo 3 Jo Jo 6 a 14 5 fo ojo QTY 27 FRONT PL GASKET 28 BEARING SEAL V480 29 BEARING CUP LM67010 30 CAP SCR 0 31 18X0 75 SH 31 HANDLE DIPSTICK OIL CHECK V480 32 DIPSTICK OIL CHECK V480 33 O RING 112 34 GAUGE OIL PSI 1 5 35 BREATHER BODY 36 COUPLER 0 50 BLK 37 BREATHER CPRSR 50NPT NY8 38 O RING 2 115 FOR OIL PICKUP TUBE 39 KEY FLYWHEEL 1 4 a2. 22686 0041 HANDLE DIPSTICK CHECK 480 O RING 112 22839 DIPSTICK V230 V360 C2279 C6235 FTG HOSE BARB 0 50 HOSE X 0 50 MNPT FTG BRASS ELL 90 DEG A C 25196 4665 23878 0 63 12 00 8 55 NIPPLE 0 75 4 00 SS 304 01266 01264 FTG 0 75 ELBOW BRASS FTG 0 75 CLOSE RED BRASS NIPPLE 5480 VALVE CHECK 0 75 STANDARD D1267 C4692 FTG 75X90 DEG ST EL BRASS 44164 FTG 0 75 JIC ML NPT 12CTX 90 DEG EL C0863 C5559 C5576 SWITCH PRES COMPRESSOR FTG ADAPT 1 8ML 1 4FM NPT 1404 2 4 FTG 0 25 HEX NIPPLE 00240 SEE PAGE 15 FOR CLUTCH OPTIONS FTG ELL 0 13 CPRSN TUBE TO NPT A 23 23 3 5 25 25 25 25 25 25 5 m 25 w m 25448 TUBE COPPER 0 25 9 00 SUH 60 Assembly Drawings 17 SHD 60 Compressor Assembly COMPRESSOR ASSEMBLY DESCRIPTION DESCRIPTION TY B0820 BASE WLDMNT SHD 60 8278 15967 MOTOR MNT SHD 60 amp SHD 43 13523 CPRSR V480CT66NP 480 C3480 D1345 CPRSN 0 12 0 25 TUBE C4779 COUPG SPIDER SUL 99 BLUE URETHANE FTG ML ELBOW 0 25 MNPT 0 125 MNPTSPL COUPLING LOVEJOY 5 8 C0863 SWITCH PRES COMPRESSOR C4492 MOTOR HYD SHD60 amp SHD43 14267 TUBING COPPER 0 25 X 9 00 14609 HOSE SUCTION 0 75 X 13 00 TE C1129 COOLER 0333 0 25 20 HHGR5 NYLOC C6145 90 DEG WASHER 0 25 FLAT 63558 MANIFOLD BLOCK SHD60 01465 WASH
3. Blowing oil from crankcase breather No lubricating oil pressure Check compressor rotation Compressor reed valves Dirty intake filter Low oil Level Check valve leaking No 12 Volt Power to Compressor Air reservoir full Hydraulic lines not connected Couplers or hoses blocked Air load against compressor Hydraulic pump not working Hydraulic motor not working Check valve leaking Compressor reed valves Check for hose leaks Hydraulic flow too low Hydraulic motor worn Power unit relief set too low Hydraulic system too hot Speed control not working Air pressure switch set wrong Leaking hoses or fittings Low compressor speed Air filter dirty Airlines leaking Check valve plugged Leaks in air line Air pressure switch set wrong Dirt in solenoid valve Dirty air filter ntake reed valves malfunction nsufficient torque on head bolts Air pressure switch set wrong Air line leak Air consumption exceeds Compressor capacity Intake or exhaust valves damaged Pressure switch not operating Internal contamination Pressure switch not adjusted Oil level too high Oil leaks Piston rings worn or broken Blown head gasket Piston rings worn or broken Oil level in crankcase too high Hole in piston Air lock in oil pump No oil in crankcase Pump suction blocked Check fittings on hydraulic motor Inspect clean or replace valves Clean filter assembly Level Add oil if needed Disassemble clean and re install
4. Installation Compressor Installation Component Installation This section pertains to the installation of the air compressor PTO pump and other related items The instructions are intended as a guide to assist you with particular installation These instructions will provide only general information Torque and Procedure Chart Pulsation Chamber Assembly Torque Value 31 FT LBS Procedure See Head Assembly Head Assembly Torque Value 31 FT LBS Procedure Assemble both heads on the cylinders with head bolts started only not tight Set pulsation chamber in place between heads making sure the O ring is in place in each head Screw the 4 chamber mounting bolts down but not tight Snug 6 head bolts in each head to light torque Tighten 4 chamber bolts to 31 Ft lbs torque Tighten 6 head bolts in each head to 31 Ft lbs torque doing the 2 long center bolts first and the 4 short bolts last After five hours of use re torque bolts to 31 Ft Ibs Cylinder Assembly Torque Value 20 FT LBS Procedure After assembling cylinder over pistons and setting into place tighten 6 cap screws finger tight In a criss cross pattern tighten bolts evenly so all bolts are hand snug Again ina criss cross pattern torque each bolt to 20 Ft Ibs checking each bolt twice After five hours of use re torque bolts to 20 Ft Ibs Connecting Rod Assembly Torque Value 18 FT LBS Procedure Assemble rod onto the crankshaft ta
5. jo Jo Jo Jo 10 Class 4 Compressor Owner s Manual Cylinder Group CYLINDER GROUP ITEM PART DESCRIPTION CYLINDER GASKET CONNECTING ROD 200 V480 O S PISTON 200 480 PISTON PIN 200 V480 SNAP RING PISTON PIN N5000 62 C6360 CYLINDER V480 FINISHED O S 7 0522 WASHERO 31LOCK 1 6 8 0922 SCR 100 0 31 18 006835 6 9 5827 RING OIL V480 200 FLEX DIVIDER 2 10 32931 RING SCRAPER V480 200 H 48638 2 T 32620 RING Vaa0i200 BARREL 2 36368 OIL V480 200 RING RAIL Assembly Drawings 11 Head Group HEAD GROUP PART DESCRIPTION 1 15195 HEAD A C THD INTAKE V480 5 1586 CAP SCR 0 38 16X1 75 SH HEAD BOLT 0040 WASHER HD BOLT STL 5828 WASHER LONG HD BOLT BRASS 1582 CAP SCR 0 38 16X3 00 SH HEAD BOLT D0887 GASKET VALVE PLATE 200 480 24103 VALVE PLATE SUB ASM 5 C0310 GASKET HEAD 143 230 360 480 0291 O RING 214 9009 75 MANIFOLD DISCHARGE ITEM PART DESCRIPTION 1 0846 V480 DISCHARGE O S 1 2 5797 DRAIN COCK V480 1 6000 PLUG 0 75 NPTSQHDCSBLK 1 4 1166 0 44 1 00 PULSATION TANK BOLT 4 12 Class 4 Compressor Owner s Manual Aluminum Air Cooled Imbedded Filter amp 3 4 Threaded NPT Discharge 301632 Aluminum Water Cooled 3 4 Threaded Inlet amp
6. 3 4 Threaded NPT Discharge 122996 Cast Iron Air Cooled Imbedded Filter amp 3 4 Threaded NPT Discharge with Head Unloader Ports Head Options 01631 Aluminum Water Cooled Imbedded Filter amp 3 4 Threaded NPT Discharge 15195 Cast Iron Air Cooled 3 4 Threaded Intake Port on Top of Head with 3 4 Discharge Port Cast Iron Air Cooled 3 4 Threaded Inlet amp 3 4 Threaded NPT Discharge 23039 Cast Iron Air Cooled 3 4 Threaded Inlet amp 3 4 Threaded NPT Discharge with Head Unloader Ports Assembly Drawings Optional Head Unloader PN 23200 DESCRIPTION 22597 BODY HEAD UNLOADERCPRSR 6 0220 568 0 2520 1 5 2 22599 GASKET UNLOADER 3 22593 PISTON HEAD UNLOADERCPRSR 2 60040 washer BOLTS f 4 22598 O RING 2 116 HEAD UNLOADER CPRSR 4 __ 9 22597 SPRING PLUNGER PIN UNLOADER CPRSR 2 5 22592 COVER HEAD UNLOADER CPRSR 13 5 Flywheel Options Assembly Drawings 15 Clutch Options 7 DUAL V 6 DUAL V 6 8 GROOVE SERPENTINE 6 8 GROOVE 6 8 GROOVE 24V SERPENTINE 12V SERPENTINE 7 SINGLE V 6 6 GROOVE STRAIGHT BORE 12V SERPENTINE 16 Class 4 Compressor Owner s Manual 50 60 Compressor Assembly ITEM 92 it We 2 6 gt A A S gt wa 2 COMPRESSOR ASSEMBLY PART C4868 DESCRIPTION CPRSR V480CWI6NP
7. Check Fuse Drain and activate pressure switch Connect lines Locate and remove restriction Relieve air pressure Check flow and pressure settings Inspect and repair Disassemble clean and reinstall or replace Inspect clean or replace valves Tighten any hose fitting leaking Check and reset flow Replace with new motor Readjust relief valve Reservoir too small Add cooler to system Check power supply and readjust Check points and setting on switch Tighten all fittings and hoses Refer to compressor too slow Clean or Replace Filters Retighten hoses Remove and clean check valve Tighten hoses and fittings Check cut in and cutout settings Remove and clean Inspect and clean filter If air back flows from air filter reed valve is faulty and needs to be replaced Tighten bolts to required torque Readjust high pressure setting nspect and tighten loose hoses Check air demand for items using the air supply nspect and replace nspect and clean nspect and clean Readjust to lower pressure Check oil level and drain if needed nspect and repair gaskets or seals Replace rings Replace gasket Replace rings Check oil level and drain Replace piston Loosen oil gauge while compressor is running When oil begins to flow from fitting tighten oil gauge Check oil level and add Remove oil intake plug and inspect intake and screen Clean blockage Troubleshooting 23 5 60 Troubleshooting If symptoms of p
8. ER 0 31 0 178 THICK C6379 FTG SWIVEL NUT ELBOW 12 6 5 C4570 SCR 0 31 24X0 75 HH NF 7 0081 0521 6359 C4914 C4499 VALVE SOLND C4961 PLUG STR HOLLOW HEX 0 38 6 HP5ON C4671 8 12 C50X JIC 90 DEG 0076 6 32 HH NYLOC 00075 SCREW 6 32X2 75 RH HD MACHINE C4695 HOOD F G SHD60 C0922 SCR 0 31 18 1 00 HHGR5 WASHER 0 31 FLAT NUT 0 31 18 HH NYLOC C4500 DECAL SHD60 5 5 NI Om nm N a C4498 ORB JIC STRT CONNT 12 F50X S C4954 ASM 0 50 TO MOTOR SHD60 OA gt gt co OD OJIN A ow rh N 18 Class 4 Compressor Owner s Manual Hydraulics Electrical 60 Control DESCRIPTION 1 C0072 TERMINAL RING H O C469 VIRE 14 G C5953 TERMINAL SPADE 14 16 10 C6202 WIRE DUPLEX 14 2 C6004 TERMINAL FEMALE DISC 16 14 01256 WIRE 14 G BLUE 6413 LOOM 38 FIBER 15917 WIRE HARNESS SHD60 43 COMPRESSORS 18939 HARNESS SHIPOUT PIGTAIL PRESSURE SWITCH HYDRAULIC MANIFOLD Ola Aaj alr COMPRESSOR 12V INP
9. GASKET BEARING CARRIER V480 015 21 OIL INTAKE PLUG BEARING CARRIER OIL PUMP V360 V480 22 TUBE OIL PICK UP BEARING CUP L44610 23 OIL INTAKE FILTER SCREEN CRANKSHAFT V480 TAPER 24 SNAP RING PISTON PIN N5000 62 BEARING CONE LM67048 25 PLUG 0 38 NPT SQ HD BLK BEARING CONE 26 23482 BEARING CARRIER V480 O S OIL PUMP DRIVE SLEEVE V480 V360 200 27 FRONT PL GASKET ROLL PIN 0 19X 50 28 BEARING SEAL V480 SPRING OIL PUMP 29 BEARING CUP LM67010 OIL PUMP TRANSFER BUSHING 30 CAP SCR 0 31 18X0 75 SH OIL PUMP 31 22686 HANDLE DIPSTICK OIL CHECK V480 PORT PLATE GASKET 32 22210 DIPSTICK OIL CHECK V480 PORT PLATE MACHINED 33 O RING 112 PORT PLATE COVER GASKET SMALL 34 GAUGE OIL PSI 1 5 PORT PLATE COVER C0062 BREATHER BODY CAP SCR 0 31 18X1 25 HHGR5 4 36 COUPLER 0 50 BLK SCREW 0 31 18X1 00 SHC 22868 BREATHER CPRSR 50NPT NY8 SCREW 0 31 18 1 00 4 38 O RING 2 115 FOR PICKUP TUBE Q o a 5 an Q 0 N 0 gt o a N BR Q 5 a N Q N a N cx Assembly Drawings 9 Crankcase Group Straight Shaft CRANKCASE GROUP PART DESCRIPTION
10. Head 1 Head 12 Optional Head Unloader 14 Flywheel 14 xn oat TT 15 SUH 60 Compressor Assembly 16 SHD 60 Compressor Assembly 17 18 SHD 60 Control 18 Typical Hydraulic Circuit for Tandum Two Part Pump with Multiple Components 19 Typical Hydraulic Circuit for Single Stage Pump with Multiple Components 19 Typical Hydraulic Circuit for Compressor with Auxiliary Cooler 20 Replacement 21 Troubleshooting 22 General Troubleshooting 22 SHD 60 1 23 Warranty 26 ii Class 4 Compressor Owner s Manual Introduction American Eagle Compressors are designed to provide safe and dependable service for a variety of operations With proper use and maintenance American Eagle Compressors will operate at peak performance for many years This manual contains information vital to the safe use and efficient operation of this unit Following the information provided within this manual can ensure the longevity of the compressor Carefully read
11. Owner s MANUAL Safety Installation Maintenance and Operation Model V480 Compressor Model SUH 60 Compressor Model SHD 60 Compressor MERICAN AGLE E M ra iii 2 Stellar Industries Inc 190 State Street PO Box 169 Garner IA 50438 800 321 3741 Fax 641 923 2811 www slellarindustries com Subject to Change without Notification Manual Part No 40984 2008 Stellar Industries Inc Last Revision 03 07 08 Class 4 Compressor Manual Revisions Date of Revision Section Revised Description of Revision Table of Contents IU OGUCHON Tu oN ad RU co 1 2 General 2 Compressor System 2 SHD 60 Drive System Description 2 3 General Operation 165 3 SHD 60 Operation 5 6 Maintenance 4 Installation gt 290 5 Compressor Installation lees 5 SHD 60 Installation 6 Pressure Setting Instructions Assembly 5 8 Crankcase Group Tapered Shaft 8 Crankcase Group Straight Shaft 9 Cylinder 10
12. UT GROUND SPEED CONTROL Hydraulics Electrical 19 Typical Hydraulic Circuit for Single Stage Pump with Multiple Components Typical Hydraulic Circuit for Two Part Pump with Multiple Components HYDRAULIC RESERVOIR STREETSIDE OUTRIGGER 20 Class 4 Compressor Owner s Manual Typical Hydraulic Circuit for Compressor with Auxiliary Cooler HYDRAULIC RESERVOIR FILTER SCREEN AUXILIARY COOLER 7 SUCTION PORT SINGLE IA HYDRAULIC PUMP COMPRESSOR RETURN PRESSURE Replacement Parts 21 Replacement Parts Overhaul Kit P N 5380 Consisting of Gasket Set 1 Ring Set 1 O Ring 2 Valve Plate 1 Bearing Oil Seal 1 Oil 1 Qt Filter 1 Gasket Set Complete P N C6363 Ring Set Complete P N C6365 Valve Plate Assembly P N D1489 Consisting of Valve Plate 1 Top Head Gasket 1 Bottom Head Gasket 1 Crankshaft With Bearings Tapered Shaft P N 23874 Straight Shaft P N 23873 Canister Filter P N 22867 Call 800 321 3741 to Order 22 Class 4 Compressor Owner s Manual Troubleshooting General Troubleshooting Compressor runs hot Compressor does not run Compressor runs too slow Compressor will not stop Air output too low pressure okay Compressor cycles not being used Air Output low Pressure Low Air pressure too low Air pressure too high High crankcase oil usage
13. and study the operator s manual before using the unit Failure to adhere to the instructions could result in property damage or even serious bodily injury to the operator or others close to the compressor A copy of this manual is provided with every compressor and shall remain with the compressor at all times Information contained within this manual does not cover all maintenance operating or repair instructions pertinent to all possible situations This manual is not binding American Eagle reserves the right to change at any time any or all of the items components and parts deemed necessary for product improvement or commercial production purposes This right is kept with no requirement or obligation for immediate mandatory updating of this manual This product manual is not intended as a training manual for beginners or unskilled operators This manual offers guidelines for correct and safe usage of the compressor maintenance and troubleshooting If more information is required or technical assistance is needed please contact AE Technical Support Some sections of this manual contain information pertaining to all American Eagle manufactured compressors and may or may not apply to your specific model If this manual becomes damaged misplaced or unreadable at any point or if you feel that any part of this manual is unclear or incorrect please contact AE Technical Support at 800 321 3741 or email at service amer
14. arranty period shall begin from the date recorded by American Eagle as the in service date This date will be derived from the completed warranty registration card In the event a warranty registration card is not received by American Eagle the factory ship date will be used New compressors will be issued on all returns within 90 days of this factory ship date After 90 days American Eagle reserves the right to issue remanufactured compressors Regardless of in service date warranty coverage does not extend beyond twenty four 24 months from date of manufacture American Eagle s obligation under this warranty is limited to and the sole remedy for any such defect shall be the repair and or replacement at American Eagle s option of the unaltered part and or component in question American Eagle after sales service personnel must be notified by telephone fax or letter of any warranty applicable damage within fourteen 14 days of its occurrence If at all possible American Eagle will ship the replacement part within 24 hours of notification by the most economical yet expedient means possible Expedited freight delivery will be at the expense of the owner Warranty claims must be submitted and shall be processed in accordance with American Eagle s established warranty claim procedure American Eagle after sales service personnel must be contacted prior to any warranty claim A return materials authorization RMA account number must be issued t
15. bles at restart 115 PSI recommended GPM to the hydraulic motor the hydraulic pump could be weak and needs to be Note Compressor kicks out replaced at 150 PSI and kicks back in at 115 PSI Weak Hydraulic Motor the hydraulic pump is supplying the recommended GPM to the hydraulic motor the hydraulic motor could be weak and needs to be replaced No lubricating oil pressure Add oil Pump suction blocked Remove oil intake plug and inspect intake screen Clean blockage Air lock in oil pump Loosen oil gauge while the compressor is running When oil begins to flow tighten the gauge pump pin is broken Replace pin Malfunctioning oil pump If the oil pressure gauge indicator is reading in the red area use a 1 4 lock washer and point it flat Remove the oil pump housing cover and place the lock washer inside the oil pump transfer bushing so it is between the pump spring and the transfer bushing If oil pressure is still low add one more lock washer If two lock washers don t increase the oil pressure replace the oil pump Troubleshooting 25 Problem Possible Cause Air Output low Dirty air filter Air Pressure Low Inspect and clean filter Insufficient torque on head bolts Tighten bolts to required torque Intake reed valves malfunction If air back flows from air filter reed valve is faulty and needs to be replaced Air pressure too low Air line leaking Inspect and tighten loose hoses Air consu
16. ck running to the outside of the compressor housing Connect the black wire to the vehicle frame or other suitable ground Mount a single throw toggle switch in a convenient location and connect the red wire from the compressor to this switch Connect the other switch terminal to a fuse holder and then to 12 volt power supply A third wire is required from the air compressor switch when connecting the speed control into the system See drawing below FAN PRESSURE SWITCH HYDRAULIC MANIFOLD COMPRESSOR 12V INPUT SPEED CONTROL Electric speed control An optional electric or electronic speed control must be used to maintain proper operating speed of the air compressor The engine speed control will automatically increase from idle to preset speed when engaged and decrease when disengaged The electric cable pull speed control Stellar P N 25740 is used on most gasoline engines The electronic speed controls are used only on Ford 7 3 and 6 0L diesel engines Proper installation instructions are provided with each system Hydraulic System The hydraulic system consists of the pump oil reservoir filters and hoses Installed on the compressor is a valve block assembly that controls the flow to the hydraulic motor To this block a 1 2 high pressure hose must be attached This hose comes from the hydraulic pumps pressure side A 3 4 minimum low pressure return line is connected to t
17. he oil cooler outlet and is routed to the oil reservoir American Eagle recommends a sufficient sized reservoir be provided which includes the proper suction and return filters The cooler on the compressor is designed and sized to cool the air compressor efficiently An auxillary oil cooler is required when additional hydraulically operated equipment are added to the hydraulic system Pressure on the return line exceeding 200 PSI can and will cause damage to the filter cooler and components of the compressor hydraulic system Return Line Installation 7 Pressure Setting Instructions Kick Out Step 1 Pressure Setting Adjustment Screw 145 150 psi Kick On Step 2 Pressure Setting Adjustment Screw 115 120 psi Turning adjustment screws clockwise increases psi settings Turning adjustment screws counterclockwise decreased psi settings Pressure Setting Instructions 1 Always set the kick out pressure setting first 145 psi minimum 150 psi maximum 2 After kick out pressure is set adjust the kick on screw setting at 115 psi minimum 120 psi maximum 3 Cycle compressor to verify correct settings 4 For questions about this procedure please contact Stellar Customer Service 8 Class 4 Compressor Owner s Manual Assembly Drawings Group Tapered Shaft RANKCASE GROUP DESCRIPTION DESCRIPTION 480 360 20 22209 ROLL 0 19 63
18. ican Eagle synthetic compressor oil P N C0087 or an equivalent synthetic oil Note There may be oil left in the crankcase from the factory bench test Overfilling may cause the compressor to back blow oil Always check the oil level and fill to the designated marking on the dipstick before putting the unit into service Check the air intake filters on each head to make certain that they are clean and unobstructed Dirty air filters are a possible cause of reduced air output To use the compressor start the engine and engage the hydraulic system with the compressor toggle switch Through the hydraulic valve manifold the system will now function automatically Once engaged adjust the engine speed control to ensure that the compressor speed does not exceed 1300 RPM under load SHD 60 Operation Notes If adjustment is necessary for cable operated speed controls loosen the jam nut on the cable end make the adjustment and retighten the jam nut For electronic operated speed controls adjust soeed adjustment screw as needed to set RPM For setting engine RPM through the chassis ECM contact local chassis dealer When the air pressure falls below 120 PSI the 12 volt electric solenoid opens allowing hydraulic oil to flow to the hydraulic drive motor then back to the manifold and through the cooler assembly Once the air pressure reaches 150 PSI the solenoid closes shutting off the oil flow to the motor and diverts the oil to the oil coo
19. icaneagleacc com For Technical Questions Information Parts or Warranty Call Toll Free at 800 321 3741 Hours Monday Friday 8 00 a m 5 00 p m CST Or email at the following addresses Technical Questions and Information Order Parts Warranty Information service americaneagleacc com parts americaneagleacc com warranty americaneagleacc com Safety Safety This manual contains vital information for the safe use and efficient operation of this unit Carefully read the operators manual before starting the unit Failure to adhere to the instructions could result in serious bodily injury or property damage Every American Eagle Compressor will provide safe and dependable service if operated according to instructions Read and understand the safety precautions given in this manual and on the decals attached to the shields Failure to do so can result in personal injury or equipment damage Operators and maintenance personnel must always comply with the safety precautions These precautions are given here for your safety Review them carefully before operating the compressor and before performing maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations Precautions Always wear safety equipment such as goggles ear plugs and head protection at all times when operating the compressor Do not inspect or clean the c
20. king care to align the machined surfaces together and tighten cap screws finger tight Tighten bolts until hand tight and torque to 18 Ft lbs Check twice the torque reading before final assembly of the cylinders 6 Class 4 Compressor Owner s Manual 60 Installation Pump Assembly The pump assembly may either be installed directly on the PTO or as an optional method may be driven by a driveline from the PTO Pump manufacturers provide specific installation information for their products and should be consulted if questions arise PTO Assembly Check with the PTO manufactures representative for specific instructions regarding your particular make model and year of vehicle As some trucks may require modification of the transmission cross member and the exhaust system the manufacturer s instructions should be followed to insure proper installation of the PTO Compressor Assembly Prepare the mounting location of the compressor by locating and drilling four 4 holes 7 16 diameter as per the mounting pattern of the air compressor base Using four 4 3 8 x 1 25 GR 5 cap screws 3 8 flat washers and 3 8 nyloc nuts secure the compressor in place The compressor is air cooled and must have a clean supply of cooling air to the fan with minimum restrictions Adequate space must be provided for proper circulation of air Electrical Connections From the air pressure switch there are two 2 wires red and bla
21. ler With the compressor engaged the main cooling system which consists of an oil cooler electric fan motor and fan continually runs drawing ambient air through the cooler fins and across the fan assembly discharging heated air past the compressor and out the cover assembly 4 Class 4 Compressor Owner s Manual Maintenance The following table is a list of routine maintenance items including service intervals Service intervals are listed as hours days or weeks whichever occurs first American Eagle recommends that these service intervals be followed Service Intervals kwxememaes o NN Inspect and clean air intake filters Clean and operate safety valves Pesca bees Check all electrical connections Check compressor reed valves Inspect and clean air check valve CHANGE CRANKCASE OIL see footnote below Under normal operating conditions oil changes are required every 3 months When operating in a dirty environment change the oil more frequently as your particular operating condition dictates USE AE SYNTHETIC COMPRESSOR OIL P N C0087 COMPRESSOR CRANKCASE CAPACITY IS 1 QUART General preventative maintenance includes maintaining proper fluid level in both systems and the general cleanliness of the equipment Proper fluids according to the specifications are required Installation 5
22. mption exceeds Compressor capacity Check air demand for items using the air supply Air pressure switch set incorrectly Readjust high pressure setting Intake or exhaust reed valves damaged Inspect and replace Air pressure too high Pressure switch not functioning correctly Inspect and clean Internal contamination Inspect and clean Pressure switch not adjusted correctly Readjust to lower pressure High crankcase oil usage External oil leaks Inspect and repair gaskets or seals Oil level too high Check oil level and if needed Piston rings worn or broken Replace rings Blowing oil from crankcase Oil level in crankcase too high Check oil level and drain breather Blown head gasket Replace gasket Piston rings worn or broken Replace ring Hole in piston Replace piston Compressor will not stop Air pressure switch set incorrectly Check points and setting on switch Leaking air hoses or fittings Tighten all fittings and hoses AGLE Ss Limited Warranty Statement American Eagle warrants products designed and manufactured by Stellar to be free from defects in material and workmanship under proper use and maintenance Products must be installed and operated in accordance with Stellar s written instructions and capacities The warranty period shall cover the following Twelve 12 month warranty on parts and Twelve 12 month repair labor The w
23. o the claiming party prior to the return of any warranty parts Parts returned without prior authorization will not be recognized for warranty consideration All damaged parts must be returned to American Eagle freight prepaid freight collect returns will be refused Freight reimbursement of returned parts will be considered as part of the warranty claim Warranty service will be performed by any American Eagle new equipment distributor or by any American Eagle recognized service center authorized to service the type of product involved or by the American Eagle factory in the event of a direct sale At the time of requesting warranty service the owner must present evidence of date of delivery of the product The owner shall be obligated to pay for any overtime labor requested of the servicing company by the owner any field service call charges and any towing and or transportation charges associated with moving the equipment to the designated repair service provider All obligations of American Eagle and its authorized dealers and service providers shall be voided if someone other than an authorized American Eagle dealer provides other than routine maintenance service without prior written approval from American Eagle In the case repair work is performed on a American Eagle manufactured product original American Eagle parts must be used to keep the warranty in force The warranty may also be voided if the product is modified or altered in any way not app
24. ompressor while the hydraulic power source is connected Accidental engagement of the tool can cause serious injury Before performing any maintenance on the compressor place a warning tag on the hydraulic power source or disconnect the hoses from the compressor motor to prevent accidental startup of the compressor Always connect hoses to the compressor before energizing the hydraulic power source Be sure all hose connections are tight both air and hydraulic Establish a training program for all operators to ensure safe operation Do not operate the compressor unless thoroughly trained or under the supervision of an instructor Do not operate the compressor if it is damaged improperly adjusted or not completely or properly assembled Never operate the compressor with any of the guards removed Do not attempt to adjust or disable the compressors air pressure relief valve This valve limits the air pressure to 150 PSI The surface of the air compressor and the plumbing between the compressor and the cooler may reach temperatures above 150 degrees Touching these surfaces during operation can cause burns The air taken in by the air compressor must be free of flammable fumes and vapors Compressor speed should not exceed 1300 RPM Use and operate this air compressor only in full compliance with all pertinent O S H A requirements and all Federal State and Local codes or requirements 2 Class 4 Compressor Owne
25. oor performance develop the following chart be used as a guide to investigate and correct the problem When diagnosing faults in operations of the air compressor always check that the hydraulic power source is supplying the correct hydraulic flow and pressure that is listed in the compressor specification section of this manual Note To Operate the American Eagle SHD 60 Compressor needs 10 GPM and 1800 PSI System Pressure Possible Cause Solution 0 2 Compressor locks up at 110 Weak Hydraulic Motor the Hydraulic pump is supplying the psi and higher while under recommended amount of fluid to the hydraulic load motor replace the hydraulic motor Note When checking Faulty Hydraulic Pump If the pump pressure is below the recommended hydraulic pump flow make GPM replace the Hydraulic pump if necessary sure the air tank is closed and the compressor is running Oil Pressure is low If the oil pressure gauge is reading in the red area the oil pressure is low See the Low Pressure entry in this troubleshooting section Compressor will not Air receiver is full Drain and activate pressure switch operate 12 Volt power is not going to the line If there is no power going to the line side of the side of the pressure switch pressure switch trace the wire back to the power source Faulty Pressure Switch If there is power going to the solenoid valve the pressure switch Hycraulic Lines not in
26. r s Manual Specifications Compressor System Description Cast Iron Crankcase Casting Heavy Ductile Iron Crankshaft Cast Aluminum Cylinder Head Micro honed Connecting Rods High Temperature Precision Pistons Tapered Roller Bearings Stainless Steel Reed Valves Pressure Lubricated System Heavy Duty Journal Bushings Oil Pressure Gauge Pulsation Manifold SHD 60 Drive System Description 10 GPM Hydraulic System 1800 PSI System Pressure 2500 PSI Pressure Relief Setting 12 VDC Solenoid Control Valve All Steel Plumbing W JIC Fittings 165 Sq In 300 BTU Cooler 361 12 Volt Cooler Fan 6061 Aluminum Manifold Direct Drive Coupling Air Pressure Control Valve General Specifications e Model V480 Weight 87 5 SHD 60 175 Ibs Displacement 9 1200 RPM 44 CFM Delivery 28 100 PSI Maximum Working Pressure 155 PSI Oil Capacity 1 Quart Cylinders Four Cylinder Single Stage Pressure switch presets Engage 115 PSI Disengage 150 PSI Operation 3 Operation General Operation Notes Each compressor is bench tested under load at the factory to ensure proper break in and operation While it is not necessary to follow any break in procedure the following checks should be made before putting the unit into service and periodically during use Before Start Up Check the oil level in the compressor with the dipstick on the unit If oil is needed use Amer
27. roved in writing by American Eagle The owner operator is responsible for furnishing proof of the date of original purchase of the American Eagle product in question Warranty registration is the ultimate responsibility of the owner and may be accomplished by the completion and return of the American Eagle product registration card provided with the product If the owner is not sure of registration he is encouraged to contact American Eagle at the address below to confirm registration of the product in question This warranty covers only defective material and workmanship It does not cover depreciation or damage caused by normal wear and tear accident mishap untrained operators or improper or unintended use The owner has the obligation of performing routine care and maintenance duties as stated in American Eagle s written instructions recommendations and specifications Any damage resulting from owner operator failure to perform such duties shall void the coverage of this warranty The owner will pay the cost of labor and supplies associated with routine maintenance The only remedies the owner has in connection with the breach or performance of any warranty on the American Eagle product specified are those set above In no event will American Eagle the American Eagle distributor dealer or any company affiliated with American Eagle be liable for business interruptions costs of delay or for any special indirect incidental or consequential cos
28. stalled Lines not installed correctly Reinstall lines Air Couplers or hoses are blocked Locate and remove restriction Inline Check Valve is leaking Disassemble clean and reinstall or replace Faulty Solenoid Valve If there is power going to the pressure switch press down on the solenoid valve bypass button If the compressor starts to operate replace the solenoid valve Compressor 15 locked up Remove the coupler and lovejoy between the compressor pump and the hydraulic motor Turn the compressor over by hand If the compressor turns over freely the pump is ok This indicates there is a possible hydraulic problem Hydraulic motor malfunctioning Inspect and repair Hydraulic pump malfunctioning Check flow and pressure settings 24 Class 4 Compressor Owner s Manual Problem Possible Cause Compressor runs hot Dirty intake filter Clean filter assembly Low oil Level Add oil if needed Inline check valve leaking Disassemble clean and re install Blown Head or Reed Valve Gasket Replace Gasket Malfunctioning reed valve Inspect clean or replace valves Compressor runs too slow Speed control not working Check power supply and readjust Check for air hose leaks Tighten any hose fitting leaking Hydraulic system too hot Reservoir too small Add cooler to system Inspect clean or replace valves Compressor hesitates or Weak Hydraulic Pump If the hydraulic pump pressure is below the stum
29. ts or damages Such costs may include but are not limited to loss of time loss of revenue loss of use wages salaries commissions lodging meals towing hydraulic fluid or any other incidental cost All products purchased by American Eagle from outside vendors shall be covered by the warranty offered by that respective manufacturer only American Eagle does not participate in or obligate itself to any such warranty American Eagle reserves the right to make changes in design or improvement upon its products without imposing upon itself the same upon its products theretofore manufactured This warranty will apply to all American Eagle Drawer Sets and Compressed Air Systems shipped from American Eagle s factory after July 1 2005 The warranty is for the use of the original owner only and is not transferable without prior written permission from American Eagle THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES AS SPECIFIED HEREIN AMERICAN EAGLE INDUSTRIES INC IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES Revision Date March 2006 Document Number 37042
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