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. ROLAIR compressors are built to last.

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. Following these instructions can help ensure years of trouble-free service.

For any additional safety or operating questions, contact your distributor or ROLAIR Customer Service at 1-800-310-3573. Do not remove or paint over warning decals. If a warning decal is missing or unreadable, discontinue use and contact ROLAIR for a free replacement.

Safety Warnings and Definitions

Safety symbols are used throughout this manual to alert you to 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.

General Warnings:

• Do not start, operate, or service this machine until you read and fully understand the owner's manual. Failure to do so could result in death or serious injury. Contact ROLAIR at 1-800-310-3573 with any questions.
• LEAD WARNING: This product contains lead. May be harmful if eaten or chewed. May generate dust containing lead. Wash hands after use. Keep out of reach of children. This product can expose you to chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. For more information, visit www.P65Warnings.ca.gov.
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Risk of Explosion or Fire

What Can Happen: Electrical components may spark. If sparks contact flammable vapors, fire or explosion can occur. Inadequate ventilation can cause overheating and fire. Unattended compressors with leaks can start unexpectedly, leading to overheating, fire, or injury. Spilled gas or vapors contacting hot engine parts or ignition sources can cause fire.

How to Avoid: Operate in a well-ventilated area away from flammable materials. Keep flammable materials stored safely away from the compressor. Maintain at least 18 inches (45 cm) clearance from walls or obstructions. Always remain in attendance while operating. Turn off and unplug when not in use. Never refuel a hot or running engine. Add fuel outdoors in a well-ventilated area, away from ignition sources.

Risk to Breathing (Asphyxiation)

What Can Happen: Compressor air is not safe for breathing; it may contain carbon monoxide, toxic vapors, or solid particles. Inhaling compressed air can cause serious injury or death. Sprayed materials (paint, insecticides, solvents) may contain harmful vapors. Gas engine exhaust fumes contain poisonous carbon monoxide.

How to Avoid: Never inhale compressed air directly. The compressor is not equipped with suitable filters for human consumption. Do not use discharge air for breathing. Operate only in well-ventilated areas. Read and follow safety instructions for sprayed materials. Use certified safety equipment. For gas engines, avoid inhaling exhaust fumes and never run a small gas engine in a closed building without adequate ventilation.

Risk of Bursting

Air Tank Safety: Air tanks require annual inspection for safety. Failure to properly and regularly drain condensed water can lead to rust and thinning of the steel tank, potentially causing a violent explosion. Modifications, alterations, or attempted repairs to the air tank can lead to explosion. Unauthorized modifications to safety valves, pressure switches, or pilot unloader valves can lead to tank explosion.

How to Avoid: Drain tanks daily or after every 4 hours of use. Replace leaking tanks immediately. Never drill, dent, weld, patch, or modify the air tank or its attachments. Never attempt to repair a damaged tank; replace it immediately. Do not alter factory pressure settings. Before starting, pull the safety valve ring to ensure it moves freely. Never operate without a factory-approved safety valve.

Attachments & Accessories: Exceeding the pressure rating of air tools, spray guns, accessories, or inflatables can cause them to explode or fly apart.

How to Avoid: Read the owner's manual before using tools or attachments to determine safe pressure ratings. Never exceed manufacturer's maximum allowable pressure ratings. Do not use the compressor to inflate small, low-pressure objects like children's toys or balls.

Risk of Injury or Property Damage When Transporting or Storing

What Can Happen: Compressor oil can leak or spill, posing fire or breathing hazards, and causing serious injury or death. Oil leaks can damage surfaces.

How to Avoid: Always keep the compressor level. When transporting, use a protective mat to prevent damage from leaks. Remove the compressor from the vehicle immediately upon arrival. If an oil leak is found, follow local safety codes for hazardous material cleanup.

Risk of Electrical Shock

What Can Happen: Failure to provide adequate grounding can result in serious injury or death from electrocution. Improper use of electrically powered devices can cause electric shock.

How to Avoid: Ensure the electrical circuit provides proper grounding, correct voltage, and adequate fuse protection. Contact ROLAIR at 800-310-3573 if unsure. Never operate outdoors in wet conditions. Never let the power cord lay in water. Do not operate with a damaged power cord or removed protective covers. Never touch the plug with wet hands. Never pull the cord to disconnect. All electrical repairs must be performed by authorized ROLAIR service personnel.

Risk from Flying Objects

What Can Happen: Serious injury and property damage can occur from debris propelled at high speeds by the compressed air stream.

How to Avoid: Always wear ANSI Z87.1 certified eye protection with side shields. Never direct the air stream, nozzle, or sprayer towards yourself, others, or animals. Turn off the compressor and drain tank pressure completely before maintenance or attaching hoses/tools.

Risk of Hot Surfaces

What Can Happen: Serious burn injuries can result from touching exposed metal parts (engine, motor, pump, lines) that become hot during operation and remain hot after shutdown.

How to Avoid: Never touch exposed metal parts during operation or for an extended period after shutdown. Do not reach around shrouds or attempt maintenance until the unit has completely cooled.

Risk from Moving Parts

What Can Happen: Serious injury or death can occur if moving parts (belts, flywheels, pulleys, fans) contact body or clothing. Electric compressors can restart unexpectedly. Operating with damaged or missing parts exposes users to moving parts.

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

Risk from Lifting

What Can Happen: Serious injury can result from attempting to lift an object that is too heavy.

How to Avoid: Always obtain assistance from others before lifting heavy objects.

Risk of Falling

What Can Happen: Compressors can vibrate and move, potentially causing falls from elevated positions, leading to damage, injury, or death.

How to Avoid: Always operate in a stable, secure position. Never operate on a roof or other elevated position. Use air hoses to reach high locations.

Risk from Noise

What Can Happen: Noise can contribute to hearing loss with prolonged use.

How to Avoid: Always wear certified hearing protection (ANSI S12.6 / S3.19).

Risk of Unsafe Operation

What Can Happen: Serious injury or death can occur if the compressor is used in an unsafe manner.

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

Risk of Damage to Air Compressor or Property

What Can Happen: Improper transport or operation can lead to major repair expenses.

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

Gas Engine Specifics

Gas-powered compressors may not have a spark-arresting muffler. If operating near flammable materials or vegetation, an approved spark arrestor is legally required in California (Public Resources Code sections 4442, 4443, Statute section 130050). Check local regulations.

Honda Engines with Electric Start

Refer to the Honda owner's manual for specific instructions. Visit engines.honda.com for manuals. Specifications for Honda engines (GX120, GX160, GX200, GX240, GX270, GX340, GX390, GX630) are provided, including charging system, fuse size, battery type, and minimum battery capacity. ROLAIR recommends draining tanks before starting, allowing the engine to run briefly with the drain open, and installing battery terminal caps.

System Controls

Detailed descriptions of various system controls are provided:

(1) SAFETY-RELIEF VALVE:

Discharges tank pressure at a predetermined setting during system failure. Check daily by pulling the ring when the tank is drained. An inoperable valve can lead to tank rupture or explosion. Do not tamper with or remove.

(2) MANUAL OVERLOAD / MOTOR RESET:

Protects the motor from overheating. If tripped, allow the motor to cool for five minutes, then push the reset button. Undersized extension cords can cause overheating.

(3) PRESSURE SWITCH:

Operates the compressor automatically between set pressures (typically 105-130 PSI). Ensure the lever is "Off" before plugging in. Move to "On/Auto" to start. Do not stop by unplugging; use the "Off" position. The lever also operates a relief valve for loadless starts.

(4) REGULATOR – WORKING PRESSURE:

Adjusts output/line pressure by lifting and rotating the knob. Clockwise increases, counterclockwise decreases. Push down to lock. Never exceed tool pressure ratings.

(5) PRESSURE GAUGE(S):

Measures tank/storage pressure and output/working pressure.

(6) DRAIN VALVE(S):

Allows daily draining of moisture from storage tank(s). Open carefully and slowly to prevent scale/rust expulsion.

(7) AIR INTAKE FILTER:

Prevents foreign matter from entering the engine or pump. Check and clean/replace elements regularly. Use warm soapy water or low compressed air for cleaning. Check canisters/elbows for cracks.

(8) PILOT-UNLOADER VALVE:

Used on gas units and can be used on electric compressors for continuous operation. Discharges compressed air to atmosphere when tank pressure reaches the top setting. Redirects air to the tank when pressure drops. Do not replace without draining tank pressure. Factory recommendations for pressure settings are provided for Direct Drive (105-130 PSI), I-Stage (110-135 PSI), and II-Stage (130-150 PSI) compressors.

(9) SIGHT GAUGE/DIPSTICK:

Used to check oil level in pump and engine. Dipstick functions as a crankcase vent. Never operate without the factory-supplied dipstick. Belt-driven units have a sight gauge; maintain oil level at 2/3 full.

(10) CHECK VALVE:

Seals and maintains tank pressure after top-end pressure setting is reached. Works with the pressure switch relief valve for a loadless start. A burst of air escaping the pressure switch relief valve indicates it's working. Mysterious leaks may indicate a check valve issue.

(11) BREATHER/OIL FILL PLUG:

Relieves crankcase pressure. Direct-drive units vent through dipstick ports; belt-drive units vent through the oil-fill plug. Never operate without the dipstick or oil-fill plug.

(12) AUTOMATIC-IDLE CONTROL:

For gas-powered units. Decreases engine speed when pilot unloader valve reaches top pressure setting. Top RPM is factory set. Idle speed is controlled by a screw on the carburetor. Adjust idle speed slightly for colder temperatures. Premature spark plug fouling occurs if idle speed is too low.

(13) COLD-START VALVE:

Allows motor/pump to warm up before tank pressure is applied. Belt-driven units have a manual drain valve on the aftercooler for cold weather starting. Open drain, run unloaded for a minute, then close.

(14) SCHMIDT BELT-TIGHTENING DEVICE (GAS UNITS ONLY):

Unique system for maintaining belt tension. Loosen locknuts, rotate adjusting bolt clockwise to achieve desired tension, then retighten locknuts.

(15) VIBRATION DAMPENER(S):

Rubber pads beneath the tank assembly protect against vibration damage.

(16) ENGINE KILL SWITCH:

Easily stops the engine. Move kill switch to "On" position before pulling recoil rope to start.

(17) ENGINE CHOKE:

Move lever fully left (closed) to start a cold engine. Move fully right (open) for operation. Partial choke operation can cause spark plug fouling and carbon buildup.

(18) FUEL SHUT-OFF VALVE:

Move to "Open" (right) only when engine is running. Close to the left when not in use. Do not move or transport with valve open.

Pre-Start Checklist

Read the manual thoroughly and understand all warnings, controls, and instructions before operating. Proper operation ensures years of reliable service.

1. Operate in a Level Position: Splash-lubricated pumps require the connecting rod dipper to stay submerged. Operation over 10 degrees can seize the pump and void warranty.
2. Operate in a Clean, Dry, and Well-Ventilated Area: Allow at least 18 inches clearance for cooling. Do not operate in rain, standing water, or areas with explosive gases/fumes. Do not operate in an enclosed area.
3. Check Oil Level Daily and Change at Regular Intervals: Refer to the maintenance section for correct oil type/weight and change intervals.
4. Inspect/Clean/Change Intake Elements Regularly: Dirt ingestion causes premature wear. Pay attention to intake filters.
5. Use Proper Air Hose: Use a properly sized air hose rather than extension cords. If an extension cord is necessary, refer to the electric extension cord table for proper gauge and maximum length.
6. Do Not Use a Generator as Power Source: Air compressors require high starting current that most generators cannot supply.
7. Check Bolts, Belts, and Hardware: Loose components cause vibration and premature failure.
8. Maintain Rubber Vibration Pads: These pads prevent excessive vibration and premature failure. Operation without them voids the warranty.
9. Drain Moisture from Air Tanks Daily: Water causes internal tank corrosion. Keep drain valves closed if storing the compressor.
10. Do Not Alter Factory RPM Settings (Gas-Powered): Factory RPM settings ensure maximum efficiency, fuel consumption, and service life. Altering them voids the warranty.

Electric Extension Cord Table: (Describes wire gauge requirements based on HP and cord length)

Operation

WARNING: Your safety and the safety of others is paramount. Read and understand this manual before operating. Contact ROLAIR Customer Service with any questions.

Wet Conditions: Do not operate or store in damp or wet conditions, or after exposure to rain, sleet, ice, snow, or moisture. This can cause electric shock and rust/ice formation, making the compressor dangerous. Operate and store in a clean, dry, well-ventilated location.

Direct-Drive Electric Operation

Ensure the compressor is ready by reviewing the "Pre-Start Checklist." Slowly open the tank drain to remove condensate, keeping it open for a few seconds after starting to warm up. Ensure the pressure switch lever is "Off" before plugging into a grounded outlet. Move the lever to "On/Auto" to build tank pressure. Rotate the regulator knob counterclockwise to 0 PSI before attaching accessories. Set working pressure by rotating the regulator knob clockwise and locking it. Use the pressure switch "On(Auto)/Off" lever to start/stop. Never stop by unplugging. Store in a warm/dry location and perform maintenance as indicated.

Belt-Drive Electric Operation

Start/Stop: Follow procedures for direct-drive electric compressors. Open the drain valve on the pump aftercooler for cold starts. Belt-driven motors should not exceed 15 starts per hour. Consult dealer for conversion kits if overload trips frequently.

Constant-Speed Operation: Use for heavy-duty periods to extend motor life and prevent overheating. If the machine is designed for continuous operation, take special care to start and stop safely. Always shut off power at the main breaker or optional switch before plugging/unplugging. Drain storage tanks and open aftercooler drain valve before starting, especially in cold temperatures. Never stop by pulling the plug; use the breaker or switch.

Dual-Control Operation: Allows easy transition between start/stop and continuous running. See Figure 1 for switching instructions. Always set the pressure switch lever to "Off" before plugging/unplugging.

Duty Cycle: Belt-driven units have S1 or 100% duty cycle motors/pumps. Direct-drive models (FC1500HBP2, FC1500HS3, JC10) have a 70% duty cycle. Continuous operation may trip the motor overload due to heat. Contact Customer Service if overload problems occur.

Gas Powered Operation

Refer to System Controls items 12, 16, 17, and 18 for engine controls (idle control, kill switch, choke, fuel shut-off). The engine throttle arm is factory set for maximum life and does not need adjustment. Use the drain valve on the aftercooler/intercooler for cold starts. Prevent dirt/debris from entering the fuel tank or obstructing airflow. Ensure regulator airflow is closed (0 PSI) before attaching accessories. A slight hissing noise during idle is normal. Store in a warm/dry location and perform maintenance.

Freezing Temperatures: Proper fluid maintenance and warm-up are mandatory. Water can turn to ice and block airflow. Drain tanks and lines after each use, leaving drain valves open. Thaw any frozen compressor completely before starting. Gradually increase temperature above freezing, then drain moisture.

Cold Weather Best Practices: Do not start a frozen compressor; thaw it first. Store in a clean, dry area above freezing. Change oil to winter grade. Open tank drains before starting and run for 45-60 seconds with drains open. Consider a de-icing fluid lubricator for air lines.

High-Altitude Operation: Lower atmospheric pressure reduces CFM output (approx. 3% per 1000 ft). Higher elevations have less dense, less cooling air, potentially requiring motor upgrades to prevent overheating. Direct-drive/hand-carry units with cold-start valves may need modification. Carburetors may need re-jetting. Contact Customer Service if performance issues arise at higher elevations.

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 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 on electric units by moving the motor 1/4 inch and repositioning belts.
• Never weld on air tanks.
• Apply heat to loosen Loctite seals on drain valves, pulleys, and flywheels before removal.

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 operate with inadequate or excessive oil; warranty does not cover failures due to incorrect oil levels. Do not use detergent oil. Unit must be level during operation.

Oil Chart: Recommended SAE Viscosity Grades are listed (10 WT, 30 WT, Semi-Synthetic, Full-Synthetic) with corresponding operating temperature ranges.

Oil Change Intervals:

• ROLAIR Standard 10 WT or 30 WT: Every 200-400 hours after break-in.
• ROLAIR Semi-synthetic: Every 1,000 - 2,000 hours.
• ROLAIR Full-synthetic: Every 2,000 - 4,000 hours.

Maintenance Schedule: A table outlines recommended maintenance tasks and their frequency (Daily, Weekly, Monthly, Quarterly, Annually).

Torque Chart: Provides torque values (Inch/Lb) for various pump types (Direct Drive, K12, K17, K18, K24, K28, K30) for components like head bolts, cylinder bolts, etc.

Pilot Valve Adjustment: Should only be performed by ROLAIR factory authorized personnel. Instructions are provided for resetting differential and setting the top end pressure, with fine-tuning steps.

Schmidt Belt-Tightening Device (Gas Units Only): Instructions for adjusting belt tension.

Drive Pulleys: Pulleys must be aligned, and belt tension set correctly to prevent motor overloading, vibration, and premature failure.

Gasoline Engine RPM Settings: A table lists RPM values (Max, Idle, Pump) for various engine models (4090 Series, 1040/2040 Series, 6590 Series, 8422/8230 Series). Factory RPM settings ensure maximum efficiency; altering them voids the warranty.

Troubleshooting

A table lists common problems, their causes, and suggested solutions.

Guarantee

Associate Engineering Corporation warrants ROLAIR compressors against defects in material and workmanship for 12 months from retail purchase or 18 months from manufacture, whichever comes first. If a defect is reported within the warranty period, the company will repair or replace the part F.O.B. their factory, after the compressor is shipped prepaid.

Associate Engineering Corporation is not liable for unauthorized repairs, replacements, adjustments, or labor costs incurred by the purchaser. This warranty is in lieu of all other warranties, expressed or implied. Associate Engineering Corporation assumes no other obligations or liabilities. The company is not liable for consequential, incidental, or special damages, or for improper compressor selection.

Quality

Associate Engineering Corporation is committed to quality control and research. They aim to provide users with all available experience and engineering. ROLAIR offers features for modern compressor needs.

Parts and Schematics

Detailed parts lists and schematics are provided for various models, including:

• Schematics: Diagrams illustrating components for models 5715K17, 6715K17, 6820K17D, 3095K18, and PMP12K17. These diagrams show the location and numbering of parts.
• Parts List: Comprehensive lists of parts with schematic numbers, descriptions, part numbers, and quantities for specific models. This includes components like pumps, motors, valves, filters, gauges, and hardware.
• Supplemental Pulley and Belt Information: Details specific pulley and belt part numbers and recommendations based on model and serial number, or pulley diameter.

Note: Descriptions of diagrams are integrated into relevant sections where possible, or summarized here. Specific part numbers and detailed schematics are extensive and would make the HTML very long. A summary is provided.