ROLAIR Portable Air Compressor Owner's Manual
This manual provides essential information for the safe and effective operation, maintenance, and troubleshooting of your ROLAIR portable air compressor. Please read and understand all instructions before use.
Introduction
Congratulations on your purchase of a ROLAIR air compressor! With over 50 years of experience, ROLAIR has established a reputation for quality and reliability. This manual is designed to help you achieve years of trouble-free service. For any questions, contact ROLAIR Customer Service at 1-800-310-3573.
Safety Warnings
Your safety and the safety of others are paramount. Pay close attention to all warnings and instructions.
Definitions of Safety Warnings
- 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 Precautions
- Read and understand the entire owner's manual before operating or servicing the machine.
- Keep out of reach of children.
- This product may expose you to chemicals, including lead, known to cause cancer and birth defects. Visit www.P65Warnings.ca.gov for more information.
Specific Hazards
- DANGER: RISK OF EXPLOSION OR FIRE
What Can Happen: Electrical sparks from components can ignite flammable vapors. Inadequate ventilation can cause overheating and fire. Unattended compressors with leaks can start unexpectedly. Fires can occur if spilled gas or vapors contact hot engine parts.
How to Avoid It: Operate in well-ventilated areas away from flammable materials. Store flammable materials securely. Keep compressor at least 18" from walls and obstructions. Never place objects on the compressor. Always attend the compressor while operating. Turn off and unplug when not in use. Add fuel outdoors only, away from ignition sources.
- DANGER: RISK TO BREATHING (ASPHYXIATION)
What Can Happen: Compressed air may contain carbon monoxide, toxic vapors, or solid particles. Inhaling exhaust fumes from gas-powered models can lead to serious injury or death.
How to Avoid It: Never inhale compressed air directly from the pump or tank. Use only certified safety equipment designed for your application. Operate only in well-ventilated areas. Avoid engine exhaust fumes.
- WARNING: RISK OF BURSTING
What Can Happen: Weakened air tanks due to rust from undrained moisture or unauthorized modifications can lead to violent explosions.
How to Avoid It: Drain tanks daily or every 4 hours. Replace leaking tanks immediately. Never drill, dent, weld, patch, or modify the air tank. Do not alter factory pressure settings. Test the safety valve regularly. Never operate without a factory-approved safety valve. Do not exceed pressure ratings for tools or inflatables.
- DANGER: RISK OF INJURY OR PROPERTY DAMAGE WHEN TRANSPORTING OR STORING
What Can Happen: Oil leaks can cause fires, breathing hazards, and damage surfaces.
How to Avoid It: Always transport and store the compressor level. Use a protective mat to prevent damage from leaks. Clean up spills according to local safety codes.
- WARNING: RISK OF ELECTRICAL SHOCK
What Can Happen: Improper grounding, damaged cords, or wet conditions can cause electric shock.
How to Avoid It: Ensure proper electrical grounding, voltage, and fuse protection. Never operate outdoors in wet conditions. Never let cords lie in water. Never use damaged cords. Do not touch plugs with wet hands. Only authorized personnel should perform electrical repairs.
- WARNING: RISK FROM FLYING OBJECTS
What Can Happen: Debris propelled by compressed air can cause injury.
How to Avoid It: Always wear ANSI Z87.1 eye protection. Never direct air stream at people or animals. Turn off and drain pressure before maintenance.
- WARNING: RISK OF HOT SURFACES
What Can Happen: Exposed metal parts become hot and can cause severe burns.
How to Avoid It: Avoid touching hot parts during and after operation. Allow the unit to cool completely before maintenance.
- WARNING: RISK FROM MOVING PARTS
What Can Happen: Belts, flywheels, and fans can cause serious injury or death if contacted.
How to Avoid It: Ensure all guards and covers are in good condition. Keep hair, jewelry, and clothing away from moving parts. Always unplug when not in use. Drain tank pressure before maintenance. Never allow children to operate the compressor. Repairs must be made by authorized personnel.
- WARNING: RISK FROM LIFTING
What Can Happen: Attempting to lift too heavy an object can cause serious injury.
How to Avoid It: Obtain assistance from others when lifting heavy objects.
- WARNING: RISK OF FALLING
What Can Happen: Compressor vibration can cause it to move, leading to falls and potential injury or damage.
How to Avoid It: Operate on a stable, secure surface. Never operate on elevated positions; use air hoses to reach high locations.
- WARNING: RISK FROM NOISE
What Can Happen: Prolonged exposure to noise can contribute to hearing loss.
How to Avoid It: Always wear certified hearing protection (ANSI S12.6 / S3.19).
- WARNING: RISK OF UNSAFE OPERATION
What Can Happen: Serious injury or death can occur if the compressor is used unsafely.
How to Avoid It: Understand all instructions. Know how to stop the compressor. Do not operate if fatigued, under the influence of alcohol/drugs, or impaired. Stay alert.
- CAUTION: RISK OF DAMAGE TO AIR COMPRESSOR OR PROPERTY
What Can Happen: Improper transport or operation can lead to expensive repairs.
How to Avoid It: Check oil levels daily. Operate on a secure, level surface. Always use an air filter. Do not operate in corrosive environments.
System Controls
Familiarize yourself with the following system controls:
- (1) SAFETY-RELIEF VALVE: Discharges excess tank pressure. Check daily by pulling the ring when the tank is drained. Do not tamper with.
- (2) MANUAL OVERLOAD / MOTOR RESET: Protects the motor from overheating. Allow motor to cool, then push reset button.
- (3) PRESSURE SWITCH: Starts and stops the compressor automatically (typically 105-130 PSI). Move lever to 'On/Auto' to start, 'Off' to stop. Never unplug to stop.
- (4) REGULATOR – WORKING PRESSURE: Adjusts output pressure. Lift knob to adjust, push down to lock. Never exceed tool pressure ratings.
- (5) PRESSURE GAUGE(S): Indicate tank/storage pressure and output/working pressure.
- (6) DRAIN VALVE(S): Used to drain moisture from the tank(s) daily. Open slowly to avoid expelling debris.
- (7) AIR INTAKE FILTER: Prevents foreign matter from entering the pump. Clean or replace regularly.
- (8) PILOT-UNLOADER VALVE: (Gas units) Discharges compressed air to atmosphere when tank pressure reaches the set point, allowing for a loadless restart.
- (9) SIGHT GAUGE/DIPSTICK: Used to check and maintain the proper oil level for the pump and engine. Maintain oil level to 2/3 full on sight gauge or at the maximum mark on dipstick.
- (10) CHECK VALVE: Seals tank pressure after reaching top end pressure setting, enabling a loadless start.
- (11) BREATHER/OIL FILL PLUG: Vents crankcase pressure. Never operate without the dipstick or oil-fill plug.
- (12) AUTOMATIC-IDLE CONTROL: (Gas units) Decreases engine speed when top pressure is reached to extend engine life.
- (13) COLD-START VALVE: (Direct-drive electric) 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).
- (14) SCHMIDT BELT-TIGHTENING DEVICE: (Gas units) Unique system for maintaining proper belt tension.
- (15) VIBRATION DAMPENER(S): Rubber pads that protect against vibration damage. Essential for proper operation.
- (16) ENGINE KILL SWITCH: Easily stops the engine. Move to 'On' position before starting.
- (17) ENGINE CHOKE: Used for cold starts. Move to 'closed' for cold start, then to 'open' after starting.
- (18) FUEL SHUT-OFF VALVE: (Gas units) Turn to 'Open' when operating, 'Closed' when not in use or transporting.
Pre-Start Checklist
Before operating, ensure the following:
- Always operate the compressor in a level position.
- Operate in a clean, dry, and well-ventilated area (at least 18" clearance).
- Check oil level daily and change at regular intervals.
- Inspect/clean/change intake elements regularly.
- Use properly sized air hose; refer to the extension cord table for proper gauge and length if an extension cord is necessary.
- Do not use a generator as a power source (unless it meets specific requirements).
- Check tension of bolts, belts, and hardware regularly.
- Maintain rubber vibration pads.
- Drain moisture from air tanks daily.
- Do not alter factory RPM settings on gas-powered compressors.
Electric Extension Cord Table
| Extension Cord Length | Motor 1/2 and 3/4 HP | Motor 1, 1-1/2, and 2 HP |
|---|---|---|
| Up to 25 ft. | 14 Ga. | 12 Ga. |
| 25 - 50 ft. | 12 Ga. | 10 Ga. |
| 50 - 100 ft. | 10 Ga. | 8 Ga. |
Operation
General: Read and understand the manual before operating. Do not operate in wet conditions.
Direct-Drive Electric
Follow pre-start checklist. Open drain valve briefly after starting to warm up. Ensure pressure switch is 'Off' before plugging in. Move to 'On/Auto' to start. Set regulator to 0 PSI before attaching hose. Set working pressure using the regulator knob. Always use the pressure switch lever to start/stop; never unplug to stop. Store in a warm, dry location.
Belt-Drive Electric
Follow similar procedures. Open drain valve for cold starts. Motors should not exceed 15 starts per hour. For constant speed operation, ensure safe start/stop procedures by using the main breaker or on/off switch. Dual controls allow transition between start/stop and continuous running. All belt-driven units have S1 or 100% duty cycle motors.
Gas Powered
Refer to System Controls for engine-related features (idle control, kill switch, choke, fuel shut-off). Throttle arm is factory set. Use pump aftercooler drain valve for cold starts. Keep fuel tank free of dirt and debris. Ensure regulator is closed (0 PSI) before attaching accessories. Store in a warm, dry location.
Freezing Temperatures
Proper fluid maintenance and warm-up are critical. Water can freeze and block air flow. Drain tanks and lines after each use and leave drain valves open. Thaw completely if frozen. Store in a dry area above freezing. Use winter-grade oil. Consider de-icing fluid for air lines.
High-Altitude Operation
Output (CFM) decreases at higher elevations. Electric motors may require upgrading due to less dense air. Carburetors on gas engines may need re-jetting. Contact Customer Service if performance issues arise.
Maintenance
Regular maintenance ensures peak condition and longevity. Always unplug and drain tanks before servicing. Allow unit to cool.
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. Unit must be level when operating.
Oil Chart & Recommendations
Recommended SAE Viscosity Grades are provided. Oil change intervals vary based on oil type (Standard, Semi-synthetic, Full-synthetic).
Maintenance Schedule
| Recommendation | Daily | Weekly | Monthly | Quarterly | Annually |
|---|---|---|---|---|---|
| Check Oil Level | X | ||||
| Drain Moisture from Tank(s) | X | ||||
| Inspect Air Filter(s) | X | ||||
| Check for Unusual Noise or Vibration | X | ||||
| Inspect Belt Guard | X | ||||
| Check for Air or Oil Leaks | X | ||||
| Clean Exterior of Air Compressor | X | ||||
| Check Condition of Vibration Pads | X | ||||
| Tighten/Retorque Bolts | X | ||||
| Check Belt Tension | X | ||||
| Check Operation of Safety Valve | X | ||||
| Change Compressor Oil | X | ||||
| Clean/Change Air Filter | X | ||||
| Perform Pump Up Time Test | X | ||||
| Check Operation of System Controls | X | ||||
| Check Air Tanks for Dents/Leaks | X | ||||
| Tank Inspection by Certified Inspector | X |
Torque Chart
Torque specifications for various bolts are provided for different pump types (Direct Drive, K12, K17, K18, K24, K28, K30).
Pilot Valve Adjustment
NOTE: This procedure should only be performed by ROLAIR factory authorized personnel. Instructions are provided for resetting the differential and setting the top end pressure, with fine-tuning guidelines. Refer to Figure 3 for valve illustration.
Schmidt Belt-Tightening Device (Gas Units Only)
Instructions for adjusting belt tension using the specific device. Refer to Figure 4.
Drive Pulleys
Ensure proper alignment and belt tension to prevent motor overloading and premature failure. Refer to Figure 5.
Gasoline Engine RPM Settings
| Model | Top RPM | Idle RPM | Pump RPM |
|---|---|---|---|
| 4090 Series | 2950 | 1900 | 1025 |
| 1040 & 2040 Series | 2775 | 1900 | 1175 |
| 6590 Series | 3150 | 1900 | 1125 |
| 8422 & 8230 Series | 3000 | 1900 | 900 |
NOTE: Factory RPM settings are for maximum efficiency. Adjusting above specifications voids the warranty.
Troubleshooting
Refer to the table below for common problems, their causes, and solutions.
| PROBLEM | CAUSE | SOLUTION |
|---|---|---|
| Pump is slow to build tank pressure | Loose/slipping belt, Excessive leaks, Blown gasket, Broken reed valve, Obstructed intake filter, Leaking regulator, Defective pilot valve | Adjust belt tension, Correct air leaks, Replace gaskets/valves/filters/regulator, Drain oil, Use proper oil, Clean/replace vent |
| Excessive oil consumption | Too much oil in crankcase, Improper weight of oil, Obstructed crankcase vent | Drain to proper level, Replace with proper oil, Clean/replace vent |
| Knocking noise | Dirty/plugged intake filter, Worn piston rings, Scored cylinder, Loose pulley or flywheel, Loose belts | Clean/replace filter, Service unit, Tighten parts, Adjust belt tension |
| Overheating compressor | Internal pump problem, Poor ventilation, Improper pump rotation | Service unit, Relocate compressor, Contact electrician |
| Electric motor dead, will not even hum | Thermal overload tripped, Reset physically broken, Loose motor leads or electrical connection, Short in power cord | Locate and push reset button, Replace overload/reset, Correct connections, Replace power cord |
| Motor trips overload/reset button | Motor is starting/stopping excessively, Overload is defective/weak, Improper gauge of extension cord, Stripped or poorly tightened motor thru bolts, Cracks in end bell or housing | Install constant speed/dual control kit, Replace overload, Use proper extension cord/hose, Retighten/replace bolts, Service unit |
| Gasoline engine is hard to start | Fouled/incorrect spark plug, Improper engine oil level, Improper weight of oil, Improper or old gas | Install proper spark plug, Fill oil to correct level, Change oil weight, Use fresh gas, Service unit |
Guarantee
ROLAIR compressors are warranted 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 non-conforming products at its discretion. Unauthorized repairs 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 quality control and research, providing users with the latest features and engineering in air compressors.
Parts List and Schematics
Detailed parts lists and schematics are provided for various ROLAIR models including 5715K17, 6715K17, 6820K17D, 3095K18, and PMP12K17. These illustrations and lists help identify and order replacement parts. Refer to the specific model number and serial number when ordering.
Contact ROLAIR Systems: 606 South Lake Street, P.O. Box 346, Hustisford, WI 53034-0346. Phone: 920.349.3281. Fax: 920.349.8861. Website: www.rolair.com.
