ROLAIR 5715MK103 Portable Air Compressor Instruction Manual

Introduction

Congratulations on your new ROLAIR air compressor!

With over 50 years of experience, ROLAIR compressors are designed for professionals, offering unsurpassed quality and reliability. This manual is for the operator's benefit. Read and understand all instructions before use.

Definitions: Safety Warnings

• [DANGER]: Imminent hazard, WILL result in death or serious injury.
• [WARNING]: Potentially hazardous situation, COULD result in death or serious injury.
• [CAUTION]: Potentially hazardous situation, MAY result in minor injury or property damage.

Safety Warnings

[DANGER]: Risk of Explosion or Fire

What Can Happen

• Electrical components spark, potentially igniting flammable vapors.
• Inadequate ventilation causes overheating and fire risk.
• Unattended compressors with leaks can start unexpectedly, causing overheating, fire, or injury.
• Spilled gas or vapors contacting hot engine parts can cause fire.

How to Avoid It

• Operate in well-ventilated areas away from flammable materials.
• Locate at least 20 ft. (6.1m) away from spray areas.
• Store flammable materials securely.
• Keep compressor clear of objects.
• Maintain at least 18" clearance from walls/obstructions.
• Operate in clean, dry, well-ventilated areas.
• Remain with the compressor while operating.
• Turn off and unplug when not in use.
• Never refuel a hot or running engine.
• Refuel outdoors in a well-ventilated area, away from ignition sources.

[DANGER]: Risk to Breathing (Asphyxiation)

What Can Happen

• Compressed air is not safe for breathing; may contain carbon monoxide, toxic vapors, or solids.
• Inhaling sprayed materials (paint, solvents) can be harmful.
• Gas engine exhaust contains poisonous carbon monoxide.

How to Avoid It

• Never inhale compressed air directly from the pump or tank.
• Compressor lacks human consumption filters. 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.

[WARNING]: Risk of Bursting

Air Tank Safety

Air tanks have a limited life and require annual inspection. Failure to drain condensed water leads to rust and thinning, risking explosion.

What Can Happen

• Rust and thinning of the air tank from condensed water can lead to explosion.
• Modifications or attempted repairs to the air tank can cause explosion.
• Unauthorized modifications to safety valves, pressure switches, etc., can lead to explosion.

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 or attachments. Discontinue use of compromised tanks.
• Never attempt to repair damaged tanks. Replace immediately.
• Do not alter components controlling tank pressure or factory settings.
• Test safety valve by pulling the ring when tank is drained.
• Never operate without a factory-approved safety valve.

Attachments & Accessories

• Exceeding pressure ratings of tools, guns, etc., can cause them to explode.
• Do not use tools/attachments before reading the manual for safe pressure ratings.
• Never exceed manufacturer's maximum allowable pressure ratings.
• Do not use compressor to inflate low-pressure items like toys or balls.

[DANGER]: Risk of Injury or Property Damage When Transporting or Storing

What Can Happen

• Oil leaks can cause fires, breathing hazards, serious injury, or death. Leaks can damage surfaces.

How to Avoid It

• Keep compressor level; never lay on its side. Use a protective mat during transport.
• Remove from vehicle immediately upon arrival. Follow local codes for cleanup of hazardous materials if leaks occur.

[WARNING]: Risk of Electrical Shock

What Can Happen

• Improper grounding can cause serious injury or death.
• Electricity can cause shock if not used properly.
• Unauthorized repairs 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 (rain, snow).
• Never let electrical cords lie in water.
• Never operate with damaged cords or covers.
• Never touch plugs with wet hands.
• Never pull cords to disconnect.
• All electrical repairs must be done by authorized ROLAIR personnel according to codes.

[WARNING]: Risk from Flying Objects

What Can Happen

• Debris propelled by compressed air can cause injury or property damage.

How to Avoid It

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

[WARNING]: Risk of Hot Surfaces

What Can Happen

• Touching hot engine, pump, or discharge lines can cause severe burns.

How to Avoid It

• Never touch exposed metal parts during or shortly after operation.
• Do not attempt maintenance until the unit has completely cooled.

[WARNING]: Risk from Moving Parts

What Can Happen

• Contact with belts, flywheels, pulleys, or fans can cause serious injury or death.
• Electric compressors can restart unexpectedly, causing injury or death.
• Operating with damaged/missing guards exposes you to moving parts.

How to Avoid It

• Ensure guards and covers are in good condition. Never operate with missing/damaged guards.
• Keep hair, jewelry, clothing, 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 ROLAIR authorized personnel.

[WARNING]: Risk from Lifting

What Can Happen

• Lifting excessively heavy objects can cause serious injury.

How to Avoid It

• Get assistance before lifting 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

• Prolonged exposure to 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 the manual.
• Know how to stop the compressor at all times.
• 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 or operation can lead to major repair expenses.

How to Avoid It

• Check oil levels daily.
• Operate on a secure and level surface.
• Do not operate without an air filter or in corrosive environments.

Gas Engine Specifics

Check for spark arresting muffler if operating near flammable materials. California requires approved spark arrestors (Section 130050, Public Resources Code).

Honda Engine Manuals

Refer to Honda owner's manual for electric start engines. Visit http://engines.honda.com for manuals.

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

Rolair Recommendations (Electric Start)

• Drain tank pressure completely before and after starting engine.
• Run with drain open for 30-40 seconds before closing to build pressure and cycle engine.
• Install battery terminal caps (boots) for safety. Search part numbers like 444L8V02, 444R8V02, 444L8V14, 444R8V14, 470N9V02.
• Terminal caps are required by Honda to prevent shorts and corrosion.

System Controls

(1) SAFETY-RELIEF VALVE: Discharges excess tank pressure. Check daily by pulling ring when tank is drained. Do not tamper.

(2) MANUAL OVERLOAD / MOTOR RESET: Trips to protect motor if it overheats. Allow to cool, then push reset button. Check extension cord usage.

(3) PRESSURE SWITCH: Starts and stops compressor automatically (typically 105-130 PSI). Use "On/Auto" lever. Never stop by unplugging.

(4) REGULATOR – WORKING PRESSURE: Adjust output pressure by lifting and rotating knob. Lock setting by pushing down. Never exceed tool pressure rating.

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

(6) DRAIN VALVE(S): Allows daily draining of moisture from tank(s). Open slowly to avoid expelling debris.

(7) AIR INTAKE FILTER: Prevents foreign matter from entering pump/engine. Clean or replace as needed. Use warm soapy water or low compressed air for cleaning.

(8) PILOT-UNLOADER VALVE (Gas units): Discharges air to atmosphere when tank reaches max pressure, preventing continuous compression. See Figure 3 for adjustment. Factory recommendations for pressure settings:

(9) SIGHT GAUGE/DIPSTICK: Check oil level daily. Maintain level at 2/3 full in sight gauge or max mark on dipstick. Never operate without dipstick or oil-fill plug.

(10) CHECK VALVE: Seals tank pressure after reaching top end setting. Provides loadless start. A burst of air from pressure switch relief valve indicates it's working.

(11) BREATHER/OIL FILL PLUG: Vents crankcase pressure. Direct-drive units vent through dipstick; belt-drive through oil-fill plug.

(12) AUTOMATIC-IDLE CONTROL (Gas units): Decreases engine speed when max pressure is reached, saving fuel and extending life. Top RPM is factory set.

(13) COLD-START VALVE: Allows motor/pump to warm up before tank pressure is applied. Belt-drive units may have a manual drain valve on aftercooler for cold starts.

(14) SCHMIDT BELT-TIGHTENING DEVICE (Gas units): Unique system for maintaining proper belt tension. Loosen locknuts, rotate bolt to adjust tension, retighten.

(15) VIBRATION DAMPENER(S): Rubber pads beneath tank assembly 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: Move lever left for cold start, right for normal operation. Partial choke can cause fouling.

(18) FUEL SHUT-OFF VALVE: Move to "Open" when operating, "Closed" when not. Do not transport with valve open.

Pre-Start Checklist

Read manual thoroughly. Understand all warnings, controls, and instructions. Proper operation ensures years of service.

1. Operate in a Level Position: Splash-lubricated pumps require oil bath submersion. Operation >10° angle voids warranty.
2. Operate in a Clean, Dry, Well-Ventilated Area: Maintain 18" clearance for cooling. Avoid rain, standing water, explosive vapors, or enclosed spaces.
3. Check Oil Level Daily & Change Regularly: Refer to maintenance section for type/schedule.
4. Inspect/Clean/Change Intake Elements: Dirt causes premature wear. Check filters daily.
5. Use Proper Air Hose, Not Extension Cords: If extension cord is necessary, use chart below. Inadequate hose size causes pressure drops.

6. Do Not Use a Generator: Compressors require high starting amps; most generators cannot provide sufficient wattage.
7. Check Bolts, Belts, Hardware Regularly: Loose parts cause vibration and premature failure.
8. Maintain Rubber Vibration Pads: Essential for preventing premature failure. Operation without them voids warranty.
9. Drain Moisture from Air Tanks Daily: Prevents internal corrosion. Keep drain valves closed if storing.
10. Do Not Alter Factory RPM Settings (Gas): Settings are optimized for performance, fuel economy, and life. Altering voids warranty.

Operation

[WARNING] Your safety is paramount. Read and understand this manual before operating.

Wet Conditions

Do not operate in damp or wet conditions. This can lead to electric shock, rust, or ice formation. Always operate and store in a clean, dry, well-ventilated location.

Direct-Drive Electric

Follow Pre-Start Checklist. Slowly open drain valve to warm up motor/pump. Ensure pressure switch is "Off" before plugging in. Move to "On/Auto" to build pressure. Set regulator to 0 PSI before attaching hose. Set working pressure using regulator knob. Always use "On/Auto" lever to start/stop. Never unplug to stop. Store in warm/dry location.

Belt-Drive Electric

Start/Stop Operation

Follow procedures for direct-drive. Open aftercooler drain for cold starts. Motor should not exceed 15 starts per hour. Consult dealer for conversion kits if overload trips frequently.

Constant-Speed Operation

Use for heavy-duty use to extend motor life and prevent overheating. If designed for continuous operation, take care to start/stop safely. Always shut off power at the main breaker before plugging/unplugging. Drain tanks and open aftercooler drain before starting, especially in cold temps. Never stop by unplugging; use breaker or switch.

Dual-Control Operation

Allows easy transition 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 and power. Excessive starts may trip overload. Some direct-drive models (FC1500HBP2, FC1500HS3, JC10) have 70% duty cycle; continuous operation may cause internal overload shutdown.

Gas Powered

Refer to System Controls (Items 12, 16, 17, 18) for engine controls. Throttle arm is locked at max RPM for maximum life. Use aftercooler/intercooler drain for cold starts. Keep fuel tank free of debris. Ensure regulator airflow is closed (0 PSI) before attaching hose. A slight hissing during idle is normal. Store in warm/dry location.

Freezing Temperatures

Proper fluid maintenance and warm-up are mandatory. Water can freeze and block airflow. Drain tanks/lines after each use and leave drains open. Thaw completely if frozen. Store in clean, dry area above freezing. Use winter-grade oil. Run with drains open for 45-60 seconds before building pressure. Consider de-icing fluid for air lines.

High-Altitude Operation

Output (CFM) decreases approx. 3% per 1000 ft. elevation. Air is less dense, motors may overheat. Direct-drive/hand-carry units may need modification. Carburetors may need re-jetting. Contact Customer Service for issues.

Maintenance

This compressor requires periodic maintenance. Always unplug and drain tanks completely before servicing. Wait for unit to cool.

IMPORTANT: Replace oil after 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 pump has cooled.
• Move motor 1/4" and roll belts back to increase tension on electric units.
• Never weld on air tanks.
• Apply heat to loosen Loctite seal on drain valves, pulleys, and flywheels before removal.

Lubrication

Check pump oil level before each use. Maintain level at max mark on dipstick or 2/3 full in sight gauge. Do not operate with inadequate or excessive oil. Cost of failures due to incorrect oil levels not covered by warranty. DO NOT USE A DETERGENT OIL! Unit must be level when operating.

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.

Torque Chart (Inch/Lb)

Determine pump type using suffix of Model number (Example: 4090HK17 uses K17 pump).

Pilot Valve Adjustment

NOTE: Should only be performed by ROLAIR factory authorized personnel.

Resetting Differential (2)

Ensure top toggle lever is positioned correctly. Loosen locknut (1) counterclockwise. Gently turn differential setting (2) clockwise until internal rod contacts steel ball. Turn differential (2) counterclockwise 1/4 turn. Tighten locknut (1).

Top-End Setting (4)

Loosen locknut (3) counterclockwise. Turn setting (4) clockwise to increase pressure, counterclockwise to decrease. Start with a low setting (one full counterclockwise turn) and proceed to fine-tuning.

Fine-Tuning Instructions

Start engine/motor and observe tank pressure. As pressure nears 100-130 PSI, pilot valve should unload (gas engine slows). If pilot valve doesn't unload by 130 PSI, slowly turn top end setting (4) counterclockwise until it unloads prematurely (at 100 PSI). Then turn (4) clockwise in 1/4 turn increments, tap internal rod, and repeat until desired setting is reached. If pilot valve "rifles" (sputters), fine-tune differential setting (2) 1/16 turn in either direction until rifling stops. Secure settings by tightening locknuts (1 & 3).

Schmidt Belt-Tightening Device (For Gas Units Only)

NOTE: Should only be performed by ROLAIR factory authorized personnel.

To tighten belt tension:

1. Loosen engine hold-down locknuts until washers spin freely.
2. Rotate 1/2" adjusting bolt clockwise until desired tension is reached.
3. Retighten locknuts to secure engine.

Drive Pulleys

Pulleys must be aligned, and belt tension set to specification. Misalignment or improper tension can cause motor overload, vibration, and premature failure.

NOTE: Engine RPMs are factory set for maximum efficiency. Adjusting above specification voids warranty.

Troubleshooting

[WARNING] Understand all safety warnings and controls before maintenance/repair. Drain tank pressure, unplug cord, and allow unit to cool.

Guarantee

Associate Engineering Corporation warrants ROLAIR compressors against defects in material and workmanship for 12 months from retail purchase date or 18 months from manufacture date, whichever occurs first. Company will repair or replace non-conforming products F.O.B. factory upon shipment prepaid by purchaser. Unauthorized repairs, adjustments, or labor costs are not covered. This warranty is in lieu of all other warranties. Associate Engineering Corporation is not liable for consequential, incidental, or special damages or improper selection for application.

Quality

Associate Engineering Corporation is committed to quality control and research. Our goal is to provide users with the best experience and engineering. ROLAIR compressors offer the latest features for modern air requirements.