Rolair Air Compressor Instruction Manual

Introduction

Congratulations on the purchase of your new ROLAIR air compressor! With over 50 years of experience building ROLAIR air compressors specifically designed for professionals, Associate Engineering Corporation has earned a reputation for providing a product unsurpassed in quality and reliability. This manual is compiled for the benefit of the operator. Do not use or allow anyone else to use your air compressor until this manual is read and all safety/operating instructions are understood.

If you have any additional safety or operating questions after reading this manual, please contact your distributor or our customer service department at 1-800-310-3573.

Safety Warnings

Safety symbols are used throughout this manual to alert you to imminently hazardous and potentially hazardous situations. The following definitions describe the level of severity for each signal word:

• DANGER: Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
• WARNING: Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
• CAUTION: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or damage to the air compressor, or other property.

Risk of Explosion or Fire

What Can Happen: Electrical components spark, potentially igniting flammable vapors. Inadequate ventilation can cause overheating and fire. Unattended compressors with leaks can restart unexpectedly, causing overheating and fire. Spilled gasoline or vapors coming into contact with hot engine parts can cause fire.

How to Avoid It: Operate in a well-ventilated area away from flammable vapors. Store flammable materials securely. Keep compressor at least 18" away from walls. Never place objects on the compressor. Remain in attendance while operating. Turn off and unplug when not in use. Never refuel a hot engine. Add fuel outdoors in a well-ventilated area.

Risk to Breathing (Asphyxiation)

What Can Happen: Compressed air may contain carbon monoxide, toxic vapors, or solid particles. Inhaling sprayed materials or engine exhaust fumes can cause serious injury or death.

How to Avoid It: Never inhale compressed air directly. Use only in well-ventilated areas. Use certified safety equipment for spraying. Avoid engine exhaust fumes.

Risk of Bursting

What Can Happen: Failure to drain condensed water can lead to rust and thinning of the air tank, potentially causing violent explosion. Modifications or attempted repairs to the air tank can lead to explosion. Unauthorized modifications to pressure-controlling components can lead to explosion.

How to Avoid It: Drain tanks daily. Replace leaking tanks immediately. Never drill, dent, weld, patch, or modify the air tank or its attachments. Never attempt to repair a damaged tank. Do not alter factory pressure settings. Test the safety valve regularly. Never operate without a factory-approved safety valve.

Attachments & Accessories

What Can Happen: Exceeding pressure ratings of tools, spray guns, accessories, or tires can cause them to explode or fly apart.

How to Avoid It: Read owner's manual for safe pressure ratings. Never exceed manufacturer's maximum allowable pressure ratings. Do not use compressor to inflate low-pressure objects like children's toys.

Risk of Injury or Property Damage When Transporting or Storing

What Can Happen: Oil leaks can cause fires, breathing hazards, serious injury, or death. Oil leaks can damage surfaces.

How to Avoid It: Keep compressor level. Use a protective mat during transport. Remove from vehicle immediately upon arrival. Follow local safety codes for cleanup of hazardous materials.

Risk of Electrical Shock

What Can Happen: Improper grounding can result in serious injury or death. Electricity can cause shock if not used properly.

How to Avoid It: Ensure proper electrical grounding, correct voltage, and adequate fuse protection. Never operate outdoors in wet conditions. Never let the power cord lie in water. Never operate with a damaged power cord. Do not touch the plug with wet hands. Never pull the cord to disconnect. All electrical repairs must be performed by authorized personnel.

Risk from Flying Objects

What Can Happen: Loose debris propelled at high speeds can cause serious injury or property damage.

How to Avoid It: Always wear ANSI Z87.1 eye protection with side shields. Never direct the air stream towards body parts, people, or animals. Turn off and drain tank pressure completely before maintenance or attaching hoses/tools.

Risk of Hot Surfaces

What Can Happen: Touching exposed metal parts can cause serious burn injuries. These parts remain hot for an extended period after shutdown.

How to Avoid It: Never touch exposed metal parts during operation or after shutdown. Do not attempt maintenance until the unit has completely cooled.

Risk from Moving Parts

What Can Happen: Contact with moving parts like belts, flywheels, pulleys, or fans can cause serious injury or death. Electric compressors can restart unexpectedly. Operating with damaged or missing parts exposes you to moving parts.

How to Avoid It: Ensure all guards and covers are in good condition. Keep hair, jewelry, clothing, and gloves away from moving parts. Avoid air vents covering moving parts. Always unplug when not in use. Drain tank pressure completely before maintenance. Never allow children or adolescents to operate. Repairs must be made by authorized personnel.

Risk from Lifting

What Can Happen: Lifting objects that are too heavy can cause serious injury.

How to Avoid It: Obtain assistance from others before lifting heavy objects.

Risk of Falling

What Can Happen: Compressor vibration can cause it to fall from a surface, resulting in injury or property damage.

How to Avoid It: Always operate on a stable and secure position. Never operate on an elevated position. Use air hose to reach high locations.

Risk from Noise

What Can Happen: Noise exposure can contribute to hearing loss.

How to Avoid It: Always wear certified hearing protection.

Risk of Unsafe Operation

What Can Happen: Unsafe operation can cause serious injury or death.

How to Avoid It: Read and understand the manual. Know how to stop the compressor. Be familiar with controls. Do not operate when fatigued, under the influence of alcohol or drugs. Stay alert and pay close attention.

Risk of Damage to Air Compressor or Property

What Can Happen: Improper transport or operation may result in major repair expenses.

How to Avoid It: Check oil levels daily. Operate in a secure and level position. Do not operate without an air filter or in a corrosive environment.

System Controls

This section identifies and describes the various controls and components of the air compressor.

1. Safety-Relief Valve: Discharges tank pressure at a predetermined setting when a system failure occurs. Check daily by pulling the ring when the tank is drained.
2. Manual Overload / Motor Reset: Protects the motor from overheating. If tripped, allow motor to cool for five minutes and push the reset button.
3. Pressure Switch: Starts and stops the compressor automatically based on pressure settings (typically 105-130 PSI). Use the lever to start/stop; do not unplug the power cord.
4. Regulator – Working Pressure: Adjusts output/line pressure. Lift knob, turn clockwise to increase, counterclockwise to decrease. Push knob down to lock. Never exceed tool pressure ratings.
5. Pressure Gauge(s): Measure tank or storage pressure and output or working pressure.
6. Drain Valve(s): Allow moisture to be drained from the tank daily. Open carefully and slowly.
7. Air Intake Filter: Prevents foreign matter from entering the engine or compressor pump. Check and clean/replace regularly.
8. Pilot-Unloader Valve: (Gas units) Discharges compressed air to atmosphere when tank reaches top pressure setting. Redirects air to tank when pressure drops. Do not replace without draining tank pressure.
9. Sight Gauge/Dipstick: Checks and maintains proper oil level for pump and engine. Functions as a crankcase vent.
10. Check Valve: Seals and maintains tank pressure after pressure switch/pilot valve reaches top setting. Provides a loadless start.
11. Breather/Oil Fill Plug: Relieves crankcase pressure. Vent through dipstick (direct-drive) or oil-fill plug (belt-drive).
12. Automatic-Idle Control: (Gas units) Automatically decreases engine speed when top pressure setting is reached.
13. Cold-Start Valve: Allows motor/pump to warm up before being subjected to tank pressure. Belt-drive units have a manual drain valve on the pump aftercooler.
14. Schmidt Belt-Tightening Device: (Gas units) Maintains proper belt tension.
15. Vibration Dampener(s): Rubber pads beneath the tank assembly protect against vibration damage.
16. Engine Kill Switch: Easily stops the engine. Move to “On” position before starting.
17. Engine Choke: Helps start a cold engine. Move lever to closed position for starting, open for operation.
18. Fuel Shut-Off Valve: (Gas units) Move to “Open” for operation, “Closed” when not in use.

Pre-Start Checklist

Before operating the air compressor, ensure the following checks are completed:

1. Always Operate in a Level Position: Ensure the dipper on the connecting rod remains submerged in the oil bath. Operation at more than a 10-degree angle can seize the pump and void the warranty.
2. Operate in a Clean, Dry, and Well-Ventilated Area: Allow at least 18" behind the belt guard for cooling. Do not operate in rain, standing water, or areas with explosive gases or fumes.
3. Check Oil Level Daily and Change at Regular Intervals: Refer to the maintenance section for oil type and change intervals.
4. Inspect/Clean/Change Intake Elements Regularly: Ingestion of dirt is a primary cause of premature wear. Check intake filters daily.
5. Use Properly Sized Air Hose Rather Than Extension Cords: Refer to the extension cord table for proper gauge and length. Inadequately sized air hose can affect tool performance.
6. Do Not Use a Generator as the Power Source: Generators may not provide sufficient wattage for inductive motors.
7. Check Tension of Bolts, Belts, and Hardware Regularly: Loose components can lead to excessive vibration and premature failure.
8. Maintain Rubber Vibration Pads: Excessive vibration can cause premature compressor failure. Operation without them voids the warranty.
9. Drain Moisture from Air Tanks Daily: Water is a byproduct of compressed air. Drain tanks after each use to combat internal corrosion. Keep drain valves closed if storing for extended periods.
10. Do Not Alter Factory RPM Settings on Gas-Powered Compressors: Altering RPM settings voids the warranty.

Operation

General Warnings: Read and understand the entire manual before operation. Do not operate in wet conditions. Operate and store in a clean, dry, well-ventilated location.

Direct-Drive Electric: Follow pre-start checklist. Slowly open tank drain to remove condensate. Ensure pressure switch lever is in “Off” before plugging in. Move lever to “On/Auto” to build pressure. Set regulator to 0 PSI before attaching hose. Set working pressure using regulator knob. Always use the pressure switch lever to start/stop; do not unplug.

Belt-Drive Electric: Follow similar procedures to direct-drive. Note motor overload limits (max 15 starts/hour). For constant speed operation, ensure power is shut off at the outlet before plugging/unplugging. Dual control allows switching between start/stop and constant speed.

Gas Powered: Refer to system controls for engine idle control, kill switch, choke, and fuel shut-off valve. Engine throttle arm is factory set. Use drain valve on aftercooler/intercooler for cold starts. Keep fuel tank clean and air flow unobstructed. Close regulator airflow before connecting hose.

Freezing Temperatures: Perform proper fluid maintenance and warm-up. Drain tanks and lines after each use. Thaw frozen compressors completely before starting. Store in a clean, dry area above freezing. Use winter-grade oil. Use de-icing fluid in lubricator if needed.

High-Altitude Operation: CFM output decreases at higher elevations. Motors may overheat due to less dense air. Carburetors may need re-jetting.

Maintenance

Regular maintenance ensures optimal performance and longevity. Always unplug the compressor and drain tanks completely before any maintenance. Wait for the unit to cool.

Important: Replace oil after the first 50 hours of operation.

Maintenance Hints:

• Use a soap/water solution to check for air leaks.
• Never clean filters with flammable solvents.
• Retorque head bolts only after the pump has cooled.
• Adjust belt tension as needed.
• Never weld on air tanks.
• Apply heat to loosen Loctite seals before removing parts.

Lubrication:

Check pump oil level before each use. Maintain oil level at the maximum mark on the dipstick or 2/3 full in the sight gauge. Do not use detergent oil. Ensure the unit is level during operation.

Oil Chart:

Recommended SAE Viscosity Grades are provided for different operating temperature ranges.

Maintenance Schedule:

A detailed schedule outlines daily, weekly, monthly, quarterly, and annually recommended maintenance tasks, including checking oil levels, draining tanks, inspecting filters, checking belts, and testing safety valves.

Torque Chart:

A torque chart provides specifications for head bolts, cylinder bolts, bearing-carrier bolts, connecting-rod bolts, and flywheel nuts for various pump types.

Pilot Valve Adjustment:

This procedure should only be performed by authorized ROLAIR personnel. It details how to reset the differential and top-end settings for the pilot valve.

Schmidt Belt-Tightening Device (Gas Units Only):

Instructions for adjusting belt tension on gas units.

Drive Pulleys:

Proper pulley alignment and belt tension are crucial for preventing motor overloading and premature failure.

Gasoline Engine RPM Settings:

Provides factory-set RPM values for various gasoline engines. Adjusting RPMs above factory specifications voids the warranty.

Troubleshooting

This section provides a table of common problems, their causes, and recommended solutions.

Guarantee

Associate Engineering Corporation warrants ROLAIR compressors against defects in material and workmanship for 12 months from the date of retail purchase or 18 months from the date of manufacture, whichever occurs first. The company will repair or replace non-conforming products at its discretion. Unauthorized repairs or adjustments are not covered. This warranty is in lieu of all other warranties. Associate Engineering Corporation is not liable for consequential, incidental, or special damages.

Quality

Associate Engineering Corporation is committed to continuous quality control and research. The goal is to provide users with the experience and engineering available in every product.

Parts List and Schematics

The manual includes detailed parts lists and schematics for various models, including the PMP12K17 pump and components for models 5715K17, 6715K17, 6820K17D, and 3095K18. This section helps in identifying and ordering replacement parts.