ROLAIR Instruction Manual

Portable Air Compressor Owner's Manual

Thank you for purchasing a ROLAIR! For questions regarding installation, operation, or maintenance, contact Customer Service at 1-800-310-3573.

Parts Information

Genuine ROLAIR replacement parts are sold nationwide through authorized dealers and service centers. Contact your dealership or ROLAIR Customer Service for troubleshooting, obtaining parts, or locating a service representative.

To order replacement parts, please provide:

• Compressor model number
• Compressor serial number
• Part name
• Part number
• Quantity required

Record of Pertinent Information

Record your compressor's model and serial number here for future reference when requesting service or parts.

Pump-Up Time Test: With the tank gauge at 0 PSI and air lines disconnected, close drain valves. Record the time it takes to build tank pressure. Periodically test against this time to ensure correct operation. Contact your ROLAIR representative if the test results differ significantly.

Introduction

Congratulations on your new ROLAIR air compressor! With over 50 years of experience, Associate Engineering Corporation is renowned for providing high-quality, reliable air compressors built to last. This manual is designed for the operator's benefit. Read and understand all safety and operating instructions before use to ensure years of trouble-free service. Contact customer service for any additional questions. Do not remove or paint over warning decals; contact us for free replacements if any are missing or unreadable.

Definitions - Safety Warnings

Safety symbols alert you to hazardous situations. Definitions describe the severity:

• 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 Safety Warnings

WARNING: Do not start, operate, or service this machine until you have read and fully understand the owner's manual. Failure to do so could result in death or serious injury. Call 1-800-310-3573 for questions.

WARNING: CONTAINS LEAD. May be harmful if eaten or chewed. May generate lead dust. Wash hands after use. Keep out of reach of children.

WARNING: This product can expose you to chemicals including lead, known to cause cancer and birth defects or other reproductive harm in California. For more information, visit www.P65Warnings.ca.gov.

SAVE THESE INSTRUCTIONS!

⚠️ DANGER: RISK OF EXPLOSION OR FIRE

What Can Happen:

• Electrical components may spark, igniting flammable vapors.
• Inadequate ventilation or restricted openings can cause overheating and fire.
• Unattended compressors with leaks can start unexpectedly, leading to fire or injury.
• Spilled gas or vapors near hot parts or ignition sources can cause fire.

How to Avoid It:

• Operate in a well-ventilated area away from flammable materials.
• Keep at least 20 ft. (6.1m) away from spraying areas.
• Store flammable materials securely.
• Never place objects on or against the compressor.
• Maintain at least 18" (45cm) clearance from walls/obstructions.
• Operate in a clean, dry, well-ventilated area.
• Remain with the compressor while it is 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.

⚠️ DANGER: RISK TO BREATHING (ASPHYXIATION)

What Can Happen:

• Compressor air may contain carbon monoxide, toxic vapors, or solids, which can cause serious injury or death.
• Sprayed materials like paint or solvents may contain harmful vapors.
• Gas engine exhaust contains odorless, colorless carbon monoxide, which can lead to serious injury or death.

How to Avoid It:

• Never inhale compressed air directly from the pump, tank, or breathing device.
• The compressor is not equipped for human consumption. Do not use discharge air for breathing.
• Operate and work only in well-ventilated areas. Follow safety instructions for sprayed materials. Use certified safety equipment.
• Operate gas engines only in well-ventilated areas. Avoid exhaust fumes. Never run a small gas engine in a closed building without adequate ventilation.

⚠️ WARNING: RISK OF BURSTING

Air Tank Safety: Air tanks have a limited life and require annual inspection. Contact your state's Division of Labor and Industries for inspector information.

Conditions Leading to Tank Explosion:

• Failure to drain condensed water leads to rust and thinning, potentially causing explosion.
• Modifications, alterations, or attempted repairs can lead to explosion.
• Unauthorized modifications to safety valves, pressure switches, or pilot unloaders can lead to explosion.

How to Avoid Tank Issues:

• Drain tanks daily or every 4 hours. Replace leaking tanks immediately.
• Never drill, dent, weld, patch, or modify the air tank or its attachments. Discontinue use and replace if any such conditions exist.
• Never attempt to repair a damaged or leaking tank; replace immediately.
• Do not adjust or substitute components controlling tank pressure or factory settings.
• Do not alter factory operating pressure settings.
• Before starting, pull the safety valve ring (with tank pressure at zero) to ensure it moves freely.
• Never operate without a factory-approved safety valve.

Attachments & Accessories: Exceeding pressure ratings of tools, accessories, or inflatables can cause them to explode.

How to Avoid Attachment Issues:

• Do not use tools/attachments without checking the manual for safe pressure ratings.
• Never exceed maximum allowable pressure ratings.
• Do not use the compressor for small, low-pressure items like children's toys.

⚠️ DANGER: RISK OF INJURY OR PROPERTY DAMAGE WHEN TRANSPORTING OR STORING

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

How to Avoid It: Keep compressor level, never on its side. Use a protective mat during transport. Remove compressor from vehicle immediately upon arrival. Follow local codes for cleanup of oil leaks.

⚠️ WARNING: RISK OF ELECTRICAL SHOCK

What Can Happen:

• Improper grounding can cause electrocution.
• Electricity can cause shock if the device is not used properly.
• Repairs by unauthorized personnel can cause injury or death.

How to Avoid It:

• Ensure proper electrical grounding, correct voltage, and adequate fuse protection. Call 800-310-3573 if unsure.
• Never operate outdoors in wet conditions.
• Never let cords lie in water.
• Do not operate with damaged cords or covers.
• Do not touch plugs with wet hands.
• Never pull cords to disconnect; use the plug.
• All electrical repairs must be done by authorized personnel per national/local codes.

⚠️ WARNING: RISK FROM FLYING OBJECTS

What Can Happen: Debris propelled at high speeds can cause injury or property damage.

How to Avoid It:

• Wear ANSI Z87.1 eye protection with side shields.
• Never direct the air stream at body, people, or animals.
• Turn off compressor and drain tank pressure completely before maintenance or attaching hoses/tools.

⚠️ WARNING: RISK OF HOT SURFACES

What Can Happen: Touching hot metal parts (engine, pump, lines) can cause severe burns. Parts remain hot after shutdown.

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

⚠️ WARNING: RISK FROM MOVING PARTS

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

How to Avoid It:

• Ensure guards/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 before maintenance.
• Never allow children/adolescents to operate.
• Repairs must be done by authorized personnel.

⚠️ WARNING: RISK FROM LIFTING

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

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

⚠️ WARNING: RISK OF FALLING

What Can Happen: Compressor vibration can cause falls from elevated surfaces, leading to injury or death.

How to Avoid It: Operate on a stable, secure surface. Never operate on roofs or elevated positions; use air hose to reach high locations.

⚠️ WARNING: RISK FROM NOISE

What Can Happen: Noise can contribute to hearing loss.

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

⚠️ WARNING: RISK OF UNSAFE OPERATION

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

How to Avoid It: Read and understand 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.

⚠️ CAUTION: RISK OF DAMAGE TO AIR COMPRESSOR OR PROPERTY

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

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

Gas Engine Warning: Spark arresting muffler may not be equipped. If operating near flammable materials, an approved spark arrestor is legally required in California. Check local/state regulations.

Honda Engines with Electric Start: Refer to Honda owner's manual. Visit http://engines.honda.com for manuals.

Honda Specifications & Recommendations:

Positive cable: AWG No. 4 x 1.5 m (5.0 ft.) maximum. Negative Cable: AWG No. 4 x 2.3 m (7.5 ft.) maximum.

ROLAIR Recommendations for Honda Engines:

• Drain tank pressure completely and leave drain valve open before and after starting the engine.
• Allow the compressor to run with the tank drain open for 30-40 seconds before closing to build tank pressure and cycle the engine.
• Install battery terminal caps (boots) over terminals and the starter solenoid post for safety.

System Controls

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. Ensure the spring-loaded valve moves freely. An inoperable valve can lead to excessive pressure buildup and tank explosion. Do not tamper with or remove the safety valve.

2. MANUAL OVERLOAD / MOTOR RESET: Electric compressors have manual overload protection. If the motor overheats, the overload sensor trips the reset button. Allow the motor to cool for approximately five minutes, then push the reset button. Check extension cord usage (gauge/length) as a potential cause of overheating.

3. PRESSURE SWITCH: Controls automatic start/stop (typically 105-130 PSI). Ensure the lever is in the "Off" position before plugging in the power cord. Move lever to "On/Auto" to start and maintain pressure. Do not unplug to stop; use the "Off" position. The lever operates a relief valve for no-load restarts.

4. REGULATOR – WORKING PRESSURE: Lift the adjustment knob to adjust pressure. Rotate clockwise to increase, counterclockwise to decrease. Push down to lock. Never exceed the tool's maximum pressure rating.

5. PRESSURE GAUGE(S): Measure tank/storage pressure and output/working pressure.

6. DRAIN VALVE(S): Allow daily draining of moisture from the storage tank(s). Open slowly to prevent scale/debris expulsion.

7. AIR INTAKE FILTER: Prevents foreign matter from entering the pump/engine. Check and clean/replace regularly. Use warm soapy water or low compressed air for cleaning. Check canisters for cracks.

System Controls (Continued)

8. PILOT-UNLOADER VALVE: Used on gas units, can be used on electric for continuous operation. Discharges air to atmosphere when tank reaches max pressure. Redirects air to tank when pressure drops. Do not replace without draining tank pressure. Adjustment instructions are in Figure 3.

9. SIGHT GAUGE/DIPSTICK: Check oil level daily. Dipstick for direct-drive, sight gauge for belt-drive. Maintain oil level at 2/3 full.

10. CHECK VALVE: Seals and maintains tank pressure. Works with the pressure switch relief valve for loadless starts. A burst of air from the relief valve indicates it's working. Check for mysterious leaks.

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 (Gas): Decreases engine speed when the pilot unloader reaches max pressure. Factory RPM settings ensure maximum performance and life. Do not alter. Idle speed is controlled by a carburetor screw. Adjust slightly for cold temperatures.

13. COLD-START VALVE: Allows motor/pump to warm up before tank pressure is applied. Belt-drive units have a manual drain valve on the aftercooler for cold starts. Open drain, run unloaded for 1 minute, then close. Repeat if struggling.

14. SCHMIDT BELT-TIGHTENING DEVICE (GAS UNITS ONLY): Unique system for belt tension. Loosen locknuts, rotate adjustment bolt clockwise to achieve desired tension, then retighten locknuts.

15. VIBRATION DAMPENER(S): Rubber pads protect against vibration damage and are crucial for proper operation.

16. ENGINE KILL SWITCH: Easily stops the engine. Do not move the throttle lever when stopping. The kill switch must be "On" to pull the recoil rope.

17. ENGINE CHOKE: Move lever left (closed) for cold start. Move right (open) for operation. Partial choke can cause plug fouling and carbon buildup.

18. FUEL SHUT-OFF VALVE: Move to "Open" (right) when operating. Move to "Closed" (left) when not operating. Do not move or transport with the valve open.

Pre-Start Checklist

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

1. Operate in a Level Position: Splash-lubricated pumps require the dipper to remain submerged in oil. Operation at >10 degrees angle may seize the pump and void the warranty.
2. Operate in a Clean, Dry, Well-Ventilated Area: Allow 18" clearance behind the belt guard for cooling. Do not operate in rain, standing water, or areas with explosive gases/fumes. Do not operate in enclosed areas.
3. Check Oil Level Daily & Change at Intervals: Refer to the maintenance section for oil type/weight and change frequency.
4. Inspect/Clean/Change Intake Elements Regularly: Dirt causes premature wear. Check filters daily.
5. Use Proper Air Hose, Not Extension Cords: Use the provided extension cord table for correct gauge and length. Inadequately sized hoses cause pressure drops.
6. Do Not Use a Generator as Power Source: Compressors require 3-5x starting current; most generators lack the necessary wattage.
7. Check Tension of Bolts, Belts, and Hardware Regularly: Loose parts cause vibration and premature failure.
8. Maintain Rubber Vibration Pads: Excessive vibration causes premature failure. Operation without them voids the warranty.
9. Drain Moisture from Air Tanks Daily: Water causes internal corrosion. Keep drain valves closed when storing.
10. Do Not Alter Factory RPM Settings on Gas Compressors: Factory settings ensure maximum performance/life. Alterations void warranty.

Electric Extension Cord Table Summary: Use appropriate gauge wire based on extension length and motor horsepower (e.g., 14 Ga. for up to 25 ft. for 1/2-3/4 HP motors).

Operation

WARNING: Your safety and the safety of others is paramount. Read and understand this manual completely before operating. Contact your distributor or customer service for any questions.

Wet Conditions: Do not operate in damp or wet conditions, or after exposure to moisture. This can cause electric shock, rust, or ice formation. Always operate and store in a clean, dry, well-ventilated location.

Direct-Drive Electric Operation:

• Review the Pre-Start Checklist.
• Slowly open tank drain to remove condensate, keeping it open for a few seconds after starting to warm up the motor/pump.
• Ensure the pressure switch lever is "Off" before plugging into a grounded outlet.
• Move the pressure switch lever to "On/Auto" to build tank pressure.
• Rotate the regulator adjustment knob counterclockwise to 0 PSI before attaching the air hose and accessory.
• Set working pressure by rotating the regulator adjustment knob clockwise and locking it.
• Always use the pressure switch "On/Auto/Off" lever to start or stop. Never unplug to stop.
• Store in a warm/dry location and perform maintenance as indicated.

Belt-Drive Electric Operation:

• Start/Stop: Follow procedures for direct-drive units. Open aftercooler drain for cold starts. Motors should not exceed 15 starts per hour; consult dealer for conversion kits if overload trips frequently.
• Constant-Speed Operation: Recommended for heavy use to extend motor life and prevent overheating. If your machine is built for continuous operation, start/stop carefully. Shut off power at the main breaker or switch before plugging/unplugging. Drain tanks and open aftercooler drain before starting, especially in cold temperatures. Never stop by unplugging; use the breaker/switch.
• Dual-Control Operation: Allows easy switching between start/stop and continuous running. See Figure 1 for switching instructions. Always set pressure switch to "Off" before plugging/unplugging.
• Duty Cycle: Belt-drive units have S1/100% duty cycle motors. Can operate continuously with proper ventilation/power. Excessive starts may trip overload. Some direct-drive models have 70% duty cycle; continuous operation may cause internal overload shutdown.

Gas Powered Operation:

• Refer to System Controls items 12, 16, 17, and 18 for engine controls (idle, kill switch, choke, fuel shut-off).
• Engine throttle arm is factory set for maximum RPM and life.
• Use the drain valve on the aftercooler or intercooler for cold starts.
• Prevent dirt/debris in the fuel tank or air flow.
• Close regulator air flow (0 PSI) before connecting hose.
• A slight hissing noise at idle is normal.
• Store in a warm/dry location and perform maintenance as indicated.

Freezing Temperatures:

• Proper fluid maintenance and warm-up are mandatory. Water can turn to ice and block air flow.
• Drain tanks/lines after each use and leave drain valves open when not in use.
• If frozen, thaw completely before starting. Gradually increase temperature, then drain moisture.
• Cold Weather Best Practices: Do not start a frozen compressor. Store in a clean, dry area above freezing. Change oil to winter grade. Open tank drains and run for 45-60 seconds before closing. Use de-icing lubricant for air lines. Contact dealer for questions.

High-Altitude Operation:

• Lower CFM at higher elevations (approx. 3% per 1000 ft).
• Air is less dense; motors may overheat and require upgrading.
• Direct-drive/hand-carry units with cold-start valves may need modification.
• Carburetors may need re-jetting. Contact Customer Service for performance issues at higher elevations.

Maintenance

Your compressor requires periodic maintenance for optimal performance. Follow the schedule and suggestions below.

NOTE: Always unplug/shut down and drain tanks completely before 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 solvent.
• Retorque head bolts only after the pump has cooled.
• Move motor 1/4" and roll belts back to increase belt tension (electric units).
• Never weld on air tanks.
• Use heat to loosen Loctite 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 when operating.

Oil Chart: Recommended SAE Viscosity Grades and operating temperature ranges are provided.

Oil Change Intervals:

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

Maintenance Schedule:

Torque Chart (Inch/Lb)

A torque chart is provided for various pump types (Direct Drive, K12, K17, K18, K24, K28, K30) and bolt types.

Pilot Valve Adjustment

NOTE: Must be performed by ROLAIR factory authorized personnel.

Resetting Differential (2): Follow instructions involving the toggle lever, locknut, differential setting, and steel ball contact.

Top-End Setting (4): Follow instructions for adjusting the top end setting via locknut and setting knob.

Fine-Tuning Instructions: Start the engine and observe tank pressure. Adjust the top end setting if the pilot valve does not unload correctly. Fine-tune the differential setting if the pilot valve "rifles" (sputters). Secure all adjustments.

Schmidt Belt-Tightening Device (Gas Units Only)

NOTE: Must be performed by ROLAIR factory authorized personnel.

Instructions are provided for increasing belt tension by adjusting the motor mounting bolts and adjustment bolt.

Drive Pulleys

Pulleys must be aligned correctly, and belt tension must meet specifications. Misalignment or improper tension can cause motor overload, excessive vibration, and premature belt/bearing failure.

Gasoline Engine RPM Settings

A table lists the maximum RPM, idle RPM, and pump RPM for various gasoline engine models (4090, 1040/2040, 6590, 8422/8230). Factory settings ensure maximum efficiency; adjusting RPMs above specifications voids the warranty.

Troubleshooting

WARNING: Ensure you understand all safety warnings and system controls before attempting maintenance or repair. Always drain tank pressure, unplug the power cord, and allow the unit to cool before servicing.

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 occurs first. The company will repair or replace defective parts FOB factory upon receipt of the compressor with prepaid freight. Unauthorized repairs or labor costs are not covered. This warranty replaces all other warranties and is not liable for consequential, incidental, or special damages or improper compressor selection.

Quality

Associate Engineering Corporation is committed to quality control and product research, providing users with extensive experience and engineering. ROLAIR lines meet varied air requirements with modern features.

Schematics and Parts Lists

Schematics are provided for models 3230K24CS, 4230K28CS, 5230K30CS, and PMP22K30. A detailed parts list is available, specifying part numbers and quantities for various models, aiding in maintenance and repair.