Transcript
Model SHd-66dd owner’S Manual
Safety • operation • Installation • Maintenance
PN 29773 Crane Mount w/Air Tank Option
PN 61378 Reservoir w/Shroud Option
PN 58708 Reservoir Option
PN 29226 23 Gal Reservoir Option
PN 61374 Shroud Option
Subject to Change without Notification. © 2013 American Eagle.
PN 65749 Enclosed Bulkhead
American Eagle, Inc. 740 N. State Street PO Box 169 Garner, IA 50438 800-392-3015 Fax: 641-923-9099 www.americaneagleacc.com
Manual Part No. 37243 Last Revision: 05/07/13
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AE SHD66DD Owner’s Manual
AE Compressor Manual Revisions Date of Revision Section Revised September 16, Assembly Drawings 2006 October 9, 2009 Assembly Drawings August 15, 2011
Description of Revision Updated the Compressor Assembly Drawing to reflect engineering changes. Updated the Compressor Assembly Drawing to reflect engineering changes. Assembly Drawings Updated the Compressor Assembly Drawing to reflect engineering changes.
Introduction
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Introduction American Eagle Compressors are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, American Eagle Compressors will operate at peak performance for many years. This manual contains information vital to the safe use and efficient operation of this unit. Following the information provided within this manual can ensure the longevity of the compressor. Carefully read and study the operator’s manual before using the unit. Failure to adhere to the instructions could result in property damage or even serious bodily injury to the operator or others close to the compressor. A copy of this manual is provided with every compressor and shall remain with the compressor at all times. Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. This manual is not binding. American Eagle reserves the right to change, at any time, any or all of the items, components, and parts deemed
necessary for product improvement or commercial/production purposes. This right is kept with no requirement or obligation for immediate mandatory updating of this manual. This product manual is not intended as a training manual for beginners or unskilled operators. This manual offers guidelines for correct and safe usage of the compressor, maintenance, and troubleshooting. If more information is required or technical assistance is needed, please contact AE Technical Support. Some sections of this manual contain information pertaining to all American Eagle manufactured compressors and may or may not apply to your specific model. If this manual becomes damaged, misplaced, or unreadable at any point, or if you feel that any part of this manual is unclear or incorrect, please contact AE Technical Support at 800321-3741 or email at
[email protected]
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741 Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST Or email at the following addresses: Technical Questions, and Information Order Parts Warranty Information
[email protected] [email protected] [email protected]
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AE SHD66DD Owner’s Manual
Table of Contents
Table of Contents Chapter 1: Safety .............................................................................5 Chapter 2: Specifications ...............................................................7 Chapter 3: Operation.......................................................................9 Head Unloading System..............................................................10 Chapter 4: Maintenance ................................................................11 Chapter 5: Installation...................................................................13 Typical Hydraulic Circuit for Tandum (Two Part) Pump with Multiple Components..............................................15 Typical Hydraulic Circuit for Single Stage Pump with Multiple Components..............................................15 Typical Hydraulic Circuit for Compressor ...................................16 with Auxiliary Cooler .................................................................16 Chapter 6: Assembly Drawings ...................................................17 Compressor Assembly ................................................................17 Optional - Compressor Assembly w/Shroud - PN 61374............18 Optional - Crane Mount Air Tank - PN 29773 ............................19 Optional - Reservoir - PN 58708.................................................20 Optional - Reservoir w/Shroud - PN 61378.................................21 Optional - 23 Gal Reservoir - PN 29226 .....................................22 Crankcase, Flywheel, Cylinders, & Centrifugal Unloader ...........23 Crankshaft, Rod, & Piston...........................................................24 Valve, Manifold, & Filter...............................................................25 Tubing Assembly .........................................................................26 Chapter 7: Replacement Parts .....................................................27 Chapter 8: Troubleshooting ........................................................29
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AE SHD66DD Owner’s Manual
Safety 5 5
Chapter 1: Safety This manual contains vital information for the safe use and efficient operation of this unit. Carefully read the operators manual before starting the unit. Failure to adhere to the instructions could result in serious bodily injury or property damage. The SHD-66DD Hydraulic Air Compressor will provide safe and dependable service if operated according to instructions. Read and understand the safety precautions given in this manual and on the decals attached to the shields. Failure to do so can result in personal injury or equipment damage. Operators and maintenance personnel must always comply with the safety precautions. These precautions are given here for your safety. Review them carefully before operating the compressor and before performing maintenance or repairs. Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations. Precautions Always wear safety equipment such as goggles, ear plugs and head protection at all times when operating the compressor. Do not inspect or clean the compressor while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury. Before performing any maintenance on the compressor, place a warning tag on the hydraulic power source or disconnect the hoses from the compressor motor to prevent accidental startup of the compressor. Always connect hoses to the compressor before energizing the hydraulic power source. Be sure
all hose connections are tight, both air and hydraulic. Establish a training program for all operators to ensure safe operation. Do not operate the compressor unless thoroughly trained or under the supervision of an instructor. Do not operate the compressor if it is damaged, improperly adjusted or not completely or properly assembled. Never operate the compressor with any of the guards removed. Do not attempt to adjust or disable the compressors air pressure relief valve. This valve limits the air pressure to 175 PSI. The surface of the air compressor and the plumbing between the compressor and the cooler may reach temperatures above 150 degrees. Touching these surfaces during operation can cause burns. The air taken in by the air compressor must be free of flammable fumes and vapors. Compressor speed should not exceed 1000 RPM. Use and operate this air compressor only in full compliance with all pertinent O.S.H.A. requirements and all Federal, State and Local codes or requirements.
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AE SHD66DD Owner’s Manual
Specifications 7
Chapter 2: Specifications Drive System Description • 17-19 GPM Hydraulic System
• 2500 PSI System Pressure
• 3000 PSI Pressure Relief Setting
• 12 VDC Solenoid Control Valve
• All Steel Plumbing W/ JIC Fittings
• 165 Sq. In., 300 BTU Cooler
• 861 CFM, 12 Volt Cooler Fan
• 6061 Aluminum Manifold
• Direct Drive Coupling
• Air Pressure Control Valve
Compressor System Description • Cast Iron Crankcase Casting
• Tapered Roller Main Bearings
• Gasket-free Integrated Cylinder/Head
• Heavy Ductile Iron Crankshaft
• Precision Balanced Flywheel
• Pressure Relief Valves in interstage and discharge
• Large Diameter Finned Inner Cooling Tubing
• Splash Lubricated System
• Positive Acting Centrifugal Head Unloaders
• Preset Pilot Control Valve
General Information • • • • • • •
Model: Weight: Cylinders: Delivery: Maximum Working Pressure: Maximum Compressor Speed: Dimensions: (w/o reservoir) (w/ reservoir) • Electrical: • Crankcase Oil Capacity: • Oil Reservoir Capacity:
Champion R30D 425 lbs. (dry) Four Cylinder(Two Stage) 46 CFM @ 175 PSI 175 PSI 1000 RPM 33.5”L x 23.5”W x 25.5”H 48.5”L x 23.5”W x 25.5”H 12 VDC 4 Quart 16 Gallons
SHD-66DD Manual
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AE SHD66DD Owner’s Manual
Operation 9
Chapter 3: Operation Each compressor is bench tested under load at the factory to ensure proper break-in and operation. While it is not necessary to follow any break-in procedure, the following checks should be made before putting the unit into service and periodically during use. Before Start-Up Inspect unit for any visible signs of damage. Check the oil level in the compressor with the dipstick on the unit. If oil is needed, use American Eagle synthetic compressor oil (P/N C0087) or an equivalent synthetic oil. Note: There may be oil left in the crankcase from the factory bench test. Overfilling may cause the compressor to back blow oil. Always check the oil level and fill to the designated marking on the dipstick before putting the unit into service. Check hoses (air and hydraulic) for weak or worn condition and make sure that all connections are secure. Check the air intake filters on each head to make certain that they are clean and unobstructed. Dirty air filters are a possible cause of reduced air output. General Information To use the compressor, start the vehicle engine and engage the hydraulic system. The compressor can now be activated using the compressor switch. This energizes the hydraulic solenoid sending oil to the hydraulic drive motor and starts the compressor. Through the air pressure switch and pilot valve, the system will now function automatically. Once engaged, adjust the engine speed control to ensure that the compressor speed does not exceed 1000 RPM under load. Adjustment instructions are provided with the speed control unit. Air Pilot Valve Operation (Head Unloading System) When the hydraulic system is engaged the compressor will pump air into the receiver until the pressure reaches 175 psi. At this time the air pilot valve senses the pressure in the receiver and engages an intake valve hold-open mechanism. The compressor will run free until the pressure in the receiver falls below 145 psi and the air pressure valve disengages the intake valve hold-open mechanism to allow the compressor to pump air. See head unloading system for detailed views and adjustment instructions on the next page. Hydraulic Motor Bypass Circuit The hydraulic motor is equipped with a bypass circuit which protects the compressor from over speed. When the compressor is pumping, all hydraulic oil flows through the hydraulic motor. When the
compressor is running free, some oil is bypassed around the hydraulic motor preventing the compressor from speeding up until the engine speed control disengages. The bypass circuit, in conjunction with the engine speed control will cause the compressor to turn very slowly when not pumping. This is normal operation. When air is again required, the engine speed control engages, the bypass circuit closes and the compressor will operate at speed. The bypass circuit is set at the factory, no adjustment is necessary. Operating Notes: This reciprocating compressor must not be used for breathing air. To do so will cause serious injury whether air is supplied direct from the compressor source or to breathing tanks for later use. Any and all liabilities for damage or loss due to injuries, death and/or property damage, including consequential damages stemming from the use of this compressor to supply breathing air will be disclaimed by the manufacturer. The use of this compressor as a booster pump and/or to compress a medium other than atmospheric air is strictly non-approved and can result in equipment damage and/or injury. Nonapproved uses will also void the warranty. Never use plastic pipe or improperly rated metal pipe. Improper piping materials can burst and cause injury or property damage.
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AE SHD66DD Owner’s Manual
Head Unloading System
Intake Valve Hold-Open Mechanism
(Route to Air Pilot Valve)
Air Pilot Valve Adjustment (See Air Pilot Valve Adjustment Detail) High Pressure Adjustment: Proceed with the following while the compressor is running. 1.) Loosen locknut (4) and back off several turns. Do not turn differential adjuster (3). 2.) Check reading on the tank pressure gauge. Set the compressor maximum pressure at 175 psi. Over pressurizing compressor will cause damage and void warranty. Turn threaded cap (1) clockwise to increase pressure or counterclockwise to decrease pressure. 3.) After pressure is set, tighten locknut (4). Be careful not to move the threaded cap (1).
Differential Pressure Adjustment: Proceed with the following while the compressor is running. 1.) Loosen locknut (2) and back off several turns. 2.) Check reading on the tank pressure gauge. Set the pressure to 30 psi differential (unload at 175 psi, reload at 145 psi). Turn nut (3) clockwise to increase differential pressure or counterclockwise to decrease differential pressure. 3.) After pressure is set, tighten locknut (2). Be careful not to move nut (3)
Maintenance 11
Chapter 4: Maintenance The following table is a list of routine maintenance items, including service intervals. Service intervals are listed as hours, days, or weeks, whichever occurs first. American Eagle recommends that these service intervals be followed. Before performing any maintenance function “Lock Out” or “Tag Out” all sources of power. Be sure all air pressure in unit is relieved. Failure to do so may result in injury or equipment damage.
Service Intervals Maintenance operation
Daily
Weekly
Monthly
Hourly
Drain air tanks Check crankcase oil level Check fittings and airlines Check hydraulic fluid level Inspect and clean air intake filters Clean and operate safety valves Clean cooling fins on radiator Inspect check valve Inspect and clean compressor valves
6
Replace hydraulic filter
6
Replace air filters
3
Tighten all fittings and fasteners
3
Check all electrical connections
3
Inspect and clean air check valve
250
CHANGE CRANKCASE OIL (see footnote below) Under normal operating conditions, oil changes are required every 3 months. When operating in a dirty environment, change the oil more frequently as your particular operating condition dictates. USE AE SYNTHETIC COMPRESSOR OIL P/N C0087. COMPRESSOR CRANKCASE CAPACITY IS 4 QUARTS. General preventative maintenance includes maintaining proper fluid level in both systems and the general cleanliness of the equipment. Proper fluids according to the specifications are required.
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AE SHD66DD Owner’s Manual
Installation 13
Chapter 5: Installation COMPONENT INSTALLATION This section pertains to the installation of the air compressor, PTO, pump and other related items. The instructions are intended as a guide to assist you with particular installation. These instructions will provide only general information. Pump Assembly: The pump assembly may either be installed directly on the PTO or as an optional method, may be driven by a driveline from the PTO. Pump manufacturers provide specific installation information for their products and should be consulted if questions arise. PTO Assembly: Check with the PTO manufactures representative for specific instructions regarding your particular make, model, and year of vehicle. As some trucks may require modification of the transmission cross member and the exhaust system, the manufacturer’s instructions should be followed to insure proper installation of the PTO.
Compressor Assembly: Prepare the mounting location of the compressor by locating and drilling four (4) holes, 9/16” diameter as per the mounting pattern of the air compressor base. Using four (4) 1/2” x 1.50” GR-5 cap screws, 1/2” flat washer, and 1/2” nyloc nut, secure the compressor in place. The compressor is air cooled, and must have a clean supply of cooling air to the fan with minimum restrictions. Adequate space must be provided for proper circulation of air. Electric speed control: An optional electric or electronic speed control must be used to maintain proper operating speed of the air compressor. The engine speed control will automatically increase from idle to a preset speed when engaged and decrease when disengaged.
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AE SHD66DD Owner’s Manual
Component Installation Continued... Motor Case Drain Routed to Hydraulic Reservoir Stellar Supplied Reservoir
Remove Shipping Cap to Install Pressure Line
Connect 1-1/4” Suction Hose to 1-1/4” Barb Fitting.
1/2” High Pressure Hydraulic Hose Length as Required
Note: There are (2) Locations that you can Plumb the Sunction Hose (Side and Bottom) 1-1/4” Hydraulic Suction Hose Length as Required
Adapter as Required to Fit Your Pump
1-1/4” Barb/Adapter to Fit Your Pump
Hydraulic Pump
Hydraulic System: Installed on the compressor is a valve block assembly that controls the flow to the hydraulic motor. To this block, a 1/2” high-pressure hose must be attached. This hose comes from the hydraulic pumps pressure side. A 1-1/4” hydraulic suction hose must be installed from the hydraulic reservoir to the hydraulic pump. (See drawing above) Note: For compressors purchased without a reservoir a 3/4” minimum low-pressure return line is connected to the oil cooler outlet and is routed to the oil reservoir. The case drain line from the hydraulic motor is also routed to the oil reservoir. American Eagle recommends a sufficient sized reservoir be provided which includes the proper suction and return filters. The cooler on the compressor is designed and sized to cool the air compressor efficiently. An auxillary oil cooler is required when additional hydraulically operated equipment are added to the hydraulic system. Pressure on the return line exceeding 200 PSI can and will cause damage to the filter, cooler, and components of the compressor hydraulic system. See Detail B See Detail A
NO C
Detail A
Detail B
NC
3/4” Hose Air Line To Air Tank
1/4” Hose
Air Sense Line to Air Tank
Check Valve
Air System: Two (2) airlines must be routed to the air tank for proper installation. The main airline is routed from the check valve to the air tank using a 3/4”(200psi) air hose. This is the main delivery line and should be free from all obstructions. A 1/4” line is routed from the air pressure valve to the air tank. This line senses the pressure in the tank and will engage and disengage the compressor automatically.
Installation 15
Typical Hydraulic Circuit for Single Stage Pump with PN 30533 Multiple Components
Typical Hydraulic Circuit for Tandum (Two Part) Pump with PN 30532 Multiple Components
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AE SHD66DD Owner’s Manual
Typical Hydraulic Circuit for Compressor with Auxiliary Cooler
HYDRAULIC RESERVOIR
FILTER FILTER SCREEN
AUXILIARY COOLER
SUCTION PORT
SINGLE HYDRAULIC PUMP
COMPRESSOR
RETURN
PRESSURE
Assembly Drawings 17
Chapter 6: Assembly Drawings Compressor Assembly 19
20 9
21 12
38
22
57
19
12
15
30
10
20 10
12
16 10
8
49 39 41
7
50
10
23
55
42
11
43 44
25
45 55
22
5
27
4 5
28
3
13
3
55
6
46 62
DESCRIPTION BASE WLDMT SHD66DD CPRSR CHMP R30DHU SPECIAL WASHER 0.50 FLAT GR8 CAP SCR 0.50-13X1.50 HHGR5 WASHER 0.50 LOCK BRKT MOTOR MOUNT 19645 POWDERCOAT BRKT WLDMT COOLER MNT LH SHD66DD BRKT WLDMT COOLER MNT RH SHD66DD BRKT LIFT SHD66DD CAP SCR 0.38-16X1.00 HHGR5 WASHER 0.38 LOCK NUT 0.38-16 HH NYLOC CAP SCR 0.50-13X2.25 HHGR5 NUT 0.50-13 HHGR5 NYLOC WASHER 0.38 FLAT CAP SCR 0.31-18X0.75 HHGR5 WASHER 0.31 USS FLAT ZINC NUT 0.31-18 HH NYLOC SCREW #6-32X2.75 RH HD MACHINE WASHER #8 SAE FLAT ZP NUT #6-32 HH NYLOC WASHER 0.38 FLAT GR8 CAP SCR 0.38-16X1.25 HHGR5 CAP 0.38 PIPE HEX 5406-CAP-6 SCREW SELF TAP #14X0.75 HWH SLOTTD FTG #12 O'RING 0.75 BARB 90 COUPG 3/8 KW L150-1.75 COUPG SPIDER L150-U BLUE URETHANE COUPG 1/4 KW L150-1.00 COOLER OIL BLOCK AL CPRSR SHD 66 FTG 90 DEG
31
47
1
PART D0825 D1346 D0790 0359 0525 19645PC D0786 D0824 D0856 0351 0523 0347 26025 C6106 0346 0420 0343 0342 D0075 5290 D0076 C6353 0335 D1254 D0613 C0484 D0792 D0793 D0791 C1129 C3075 C6145
QTY. 1 1 12 8 10 1 1 1 1 14 6 10 2 2 4 2 2 2 3 9 3 8 2 1 1 1 1 1 1 1 1 1
ITEM 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
64
63
34 TORQUE: 35 FT.-LBS. TORQUE: 25 FT.-LBS. 33
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
48
59
54
2
60
14
3
53
5
58
15
52 56
11
11
22
51
24
37
29
36 4
26
36
10
18
17
48
PART C4914 C4913 C4227 31279 D1116 d0840 4703 8277 C0864 20330 C5662 5418 C2274 C5549 2772 C6015 10659 4581 D0847 16711 D1264 5480 20326 20458 29227PC 29228PC C4671 57195 58822 10973 D1189 58821
35
32
61
DESCRIPTION VALVE RELIEF CP-200-1-B-0-A-C VALVE SOLND FTG MF/MSTR 90 8-12 C5OLO-S CLAMP 0.31 BLK VINYL FTG STR THREAD ELBOW 45 DEG FAN 12.00 PUSH 12 VOLT SPL 301003 BRKT UNLOADER VALVE MNT SHD66DD FTG ST L 0.25 MNPT/0.125 FNPT SPL SWITCH PRES HOBBS FTG 0.38-0.25 FF HEX NIPPLE FILTER METAL BOWL 0.25 ST EL 0.25 90 DEG BRASS 44-161 FTG HOSE BARB .25 HOSE X .25 MNPT FTG ORB/JIC STRT CONNT 12-F5OX-S CAP 8FNL-S FTG 0.75 PLUG 12-P5ON CPLR 0.75 BRASS NIPPLE 0.75X4.00 BRASS BRKT 11.00 TWIST 45 DEG SHD66DD FTG 0.75-TEE BRASS 80101-12 FTG 0.75-CLOSE RED BRASS NIPPLE VALVE CHECK 0.75 STANDARD PLUG 0.25 NPT SQ HD BRASS NIPPLE 0.38X4.00 BRASS COVER SHD66DD FAN 9000 BRKT CPRSR ASM SHD66 9000 FTG 8-12 C50X JIC 90 DEG HYDRO MOTOR VON RUDEN TUBE ASM 0.75 BTTM CLR SHD66 W/RSMTR FTG ADAPT MSTR/FSTR 6410-12-12 FTG ST TH CONNECT JIC 8-12 F5OX TUBE ASM 0.50 PRES SHD66 W/RSMTR
QTY. 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 4 1 1 2 1 1 1 1 1 1
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AE SHD66DD Owner’s Manual
Optional - Compressor Assembly w/Shroud - PN 61374 106
107
108 107
105
102 96 84
85
86 87 100
99
97 104
103 102
93 95
98 94
96
96 88
PN 61374 ITEM 84 85 86 87
PART 5917 8158 C2229 C6243
DESCRIPTION FTG 0.25-TEE BRASS NIPPLE 0.25 X CLOSE BRASS FTG 0.25-0.13 BUSH HEX FTG CPRSN 0.12NPT/0.25 TUBE
QTY. 1 1 1 1
88
38525
BASE WLDMT SHD66DD ENCLOSURE
1
93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108
21649 28855 18611 C6021 0340 0333 22161 C6245 19589 19592 C0081 38527PC 38529PC 38530PC 38532PC 38533PC
GAUGE AIR SWICHGAGE PSB20PHL200 HOUR METER 12VDC TST 180-1911 SCREW #6-32X0.38 HH MACH SELF TAP CAP SCR 0.25-20X0.75 BTNHD SS WASHER 0.25 FLAT NUT 0.25-20 HHGR5 NYLOC CPLR 0.13 BRASS FTG ADAPT TUBE-MNPT 90 1/4-1/8 BRASS NUT SERT 0.25-20X0.38 OD WASHER 0.25 FLAT NYLON CLAMP 0.50 BLK VINYL PANEL GAUGE MNT SHD66 PANEL SIDE GAUGE SHD66 SHROUD PANEL SIDE SHD66 SHROUD PANEL END COOLER SHD66 PANEL TOP SHD66 SHROUD
1 1 2 24 2 2 1 1 16 22 1 1 1 1 2 1
Assembly Drawings 19
Optional - Crane Mount w/Air Tank - PN 29773 2
7 8 3 4
5
9 6
1
PN 29773 ITEM 1 2 3 4 5 6 7 8 9
PART 43907 58708 0335 C6353 0347 6595 C0922 0343 0342
DESCRIPTION AIR TANK ASM 20 GAL W/FTG CRANE MNT CPRSR ASM SHD66DD W/RSM W/RSRVR 20 GAL CAP SCR 0.38-16X1.25 HHGR5 WASHER 0.38 FLAT GR8 NUT 0.38-16 HH NYLOC VIBRAT INSULATOR 250# MCMASTER-CAR CAP SCR 0.31-18X1.00 HHGR5 WASHER 0.31 USS FLAT ZINC NUT 0.31-18 HH NYLOC
QTY. 1 1 4 4 4 4 8 16 8
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AE SHD66DD Owner’s Manual
Optional - Reservoir - PN 58708 29 5
5
20
4
8
14
21
17
3
17
22 6
2
16 25
27 14
31 24
21 28 6 13 29
10 33
9
1
7 18
19 16
15 12
PN 58708 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
PART D0822 D0830 D1053 D1080 D1253 D1267 C2276 c4286 C4663 C4955 C5511 C5552 C6014 c6226 0523 0351 4581 5422 5594 13188 16145 18552 20328 20452 20884 22870 C6353 D1254 C6227 C2282 0347 26480 58970
DESCRIPTION RSRVR WLDMT 16GAL SHD66DD BRKT RSRVR MOUNT SHD66DD ELBOW 0.75 90 DEG BLK TUBE ASM 0.75 RETURN SHD66DD YZ FTG ML NPTF PIPE PARKRIMP 6XHL6 FTG .75X90 DEG ST EL BRASS 44164 FTG HOSE BARB 0.38 HOSE X 0.38 MNPT FTG 12MNPT/12MJIC HOSE CLAMP #6 SS SIGHT GAUGE 3/4 NPT EYE VALVE BALL 1.25 FILTER STRAINER TFS-1220-0 FTG ADAPT 8-12 FOLO-S FILTER HEAD WASHER 0.38 LOCK CAP SCR 0.38-16X1.00 HHGR5 NIPPLE 0.75X4.00 BRASS FTG PLUG 0.75 BRASS 44-634 PLUG 2.00 NPT SQ HD CS BLK HOSE HYD 0.38X24.00 GAUGE PRES FILTER SERVICE CI20 CAP FILL ASM W/NECK PLUG 1.00 NPT SQ HD CS BRASS ELBOW 0.38 90 DEG BRASS NIPPLE 0.75X4.00 BRASS NIPPLE 1.25XCLOSE BRASS 40-125 WASHER 0.38 FLAT GR8 CAP 0.38 PIPE HEX 5406-CAP-6 FILTER SHORT FTG 1.25 NPT TO 1.25 BARB NUT 0.38-16 HH NYLOC HOSE 0.38X14.00 RED ORTAC GDYR CPRSR ASM SHD66 W/RSM WORSRVR
QTY. 1 1 1 1 2 2 1 1 1 1 1 1 1 2 2 3 2 1 2 1 2 1 1 1 1 1 2 1 2 1 1 1 1
26 19
11 30
Assembly Drawings 21
Optional - Reservoir w/Shroud - PN 61378 3
4 6 5 7
2
24
23
22
21
1
19
8
10
20
33
11 13
34
14
35
25
36
12 26 37
38
39
40 41 37
42
17 27
16
28 30 29
11 30
32
31
8
18
15
9
PN 61378 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
PART 38525 D1346 38533PC 38532PC 38529PC 38530PC 51166PC 0351 0523 0347 C6353 4581 18552 5422 D0822 C2282 C5552 5594 D0830 26480 16145
DESCRIPTION BASE WLDMT SHD66DD ENCLOSURE CPRSR CHMP R30DHU SPECIAL PANEL TOP SHD66 SHROUD PANEL END COOLER SHD66 PANEL SIDE GAUGE SHD66 SHROUD PANEL SIDE SHD66 SHROUD PANEL END COOLER SHD66 W/RSRVR CAP SCR 0.38-16X1.00 HHGR5 WASHER 0.38 LOCK NUT 0.38-16 HH NYLOC WASHER 0.38 FLAT GR8 NIPPLE 0.75X4.00 BRASS CAP FILL ASM W/NECK FTG PLUG 0.75 BRASS 44-634 RSRVR WLDMT 16GAL SHD66DD FTG 1.25 NPT TO 1.25 BARB FILTER STRAINER TFS-1220-0 PLUG 2.00 NPT SQ HD CS BLK BRKT RSRVR MOUNT SHD66DD HOSE 0.38X14.00 RED ORTAC GDYR GAUGE PRES FILTER SERVICE CI20
QTY. 1 1 1 1 1 1 1 13 6 9 12 3 1 2 1 1 1 2 1 1 1
ITEM 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
PART C6226 C4286 D1080 C6227 D1266 C4663 C2276 13188 D1253 0553 D1254 C6245 22161 38527PC 21649 C6021 18611 28855 0340 0333 19592
DESCRIPTION FILTER HEAD FTG 12MNPT/12MJIC TUBE ASM 0.75 RETURN SHD66DD YZ FILTER SHORT FTG 0.75 ELBOW BRASS HOSE CLAMP #6 SS FTG HOSE BARB 0.38 HOSE X 0.38 MNPT HOSE HYD 0.38X24.00 FTG ML NPTF PIPE PARKRIMP 6XHL6 ST EL 2102-6-6 CAP 0.38 PIPE HEX 5406-CAP-6 FTG ADAPT TUBE-MNPT 90 1/4-1/8 BRASS CPLR 0.13 BRASS PANEL GAUGE MNT SHD66 GAUGE AIR SWICHGAGE PSB20PHL200 CAP SCR 0.25-20X0.75 BTNHD SS SCREW #6-32X0.38 HH MACH SELF TAP HOUR METER 12VDC TST 180-1911 WASHER 0.25 FLAT NUT 0.25-20 HHGR5 NYLOC WASHER 0.25 FLAT NYLON
QTY. 1 1 1 1 1 2 1 1 2 1 2 1 1 1 1 8 2 1 2 2 6
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AE SHD66DD Owner’s Manual
Optional - 23 Gal Reservoir - PN 29226
23
16
1
28
2 11
13 9
5 4
27 25 12
6
24
7 22
8
26
19
14 15
21
29
10
3 17 20 18
ITEM 1
PART 0523
2
9843
3 4 5
10967 16145 20451
6
20462
7
22824
8
22826
9 10 11 12 13 14 15 16
25465 30013 30482 30492 30493 52628 54393 58970
17
C1057
18 19 20 21 22 23 24 25 26 27 28 29
C2282 C4663 C5511 C6014 C6025 C6145 C6166 C6167 C6225 C6228 C6353 D1263
DESCRIPTION WASHER 0.38 LOCK CAP SCR 0.38-16X0.75 HHGR8 (TRQ 33 FT/LBS) FTG 32-20 MP-FP REDUCER BUSHING GAUGE PRES FILTER SERVICE CI20 FTG 2-2 MP-FP STREET ELBOW 90 BRASS FTG 20-20X2.50 MP-MP NIPPLE STRAIGHT BRASS FTG 20-20 FP-FP 90 BRASS FTG 20-20X9.00 MP-MP NIPPLE STRAIGHT BRASS FTG 2-2 MP-FP STRAIGHT EXPANDER RSRVR ASM 23 GAL/SHD66 TUBE ASM 9000/SHD66 YZ FTG 16-16-16 FP-FP-MP BRANCH TEE FTG 12-16 MJ-MP STRAIGHT FTG 8-12 FORB-MP STRAIGHT SWITCH TEMP NC TT-F5B-100R-MP CPRSR ASM SHD66 W/RSM WORSRVR FTG 20-20XCLOSE MP-MP NIPPLE STRAIGHT BLK FTG 1.25 NPT TO 1.25 BARB HOSE CLAMP #6 SS VALVE BALL 1.25 FTG 8-12 MFS-MP STRAIGHT FTG 12-12-12 MP-FP-FP STREET TEE FTG 90 DEG BUSHING 1.00X0.75 STL REDU BUSHING 1.25X1.00 STL FILTER LARGE SE-10 FILTER HEAD SF120-25 1.3 WASHER 0.38 FLAT GR8 FTG HOSE BARB 0.38 HOSE X 0.38 90DG
QTY. 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1
Assembly Drawings 23
Crankcase, Flywheel, Cylinders, & Centrifugal Unloader
24
AE SHD66DD Owner’s Manual
Crankshaft, Rod, & Piston
Assembly Drawings 24
Assembly Drawings
Valve, Manifold, & Filter
25
26
AE SHD66DD Owner’s Manual
Tubing Assembly
ITEM 1 2 3 4 5 6 7 8 9 10 11 12
PART No. 7473 7474 7475 7476 7477 7476 7478 D1873 D1872 5592 5593 7479
DESCRIPTION TUBE FITTING RELEASE VALVE TUBE W/FITTINGS (ITEMS 1&3) TUBE FITTING TUBE FITTING BREATHER TUBE W/FITTINGS (ITEMS 4&6) TUBE FITTING TUBE, DISCHARGE INTERCOOLER TUBE W/FTGS RH INTERCOOLER TUBE W/FTGS LH TUBE, DISCHARGE TUBE FITTING PIPE TEE
qty 1 1 1 1 1 1 1 1 1 1 2 1
Replacement Parts 27 27
Chapter 7: Replacement Parts Hydraulic Replacement Components Part Number
Description
C4914
Relief valve
C4913
Solenoid valve
57195
Hydraulic motor
C1129
Oil cooler
C3075
Aluminum manifold block
C2029
O-ring #8 face seal
D1244
O-ring #12 face seal
D1247
O-ring #8 SAE port seal
D1249
O-ring #12 SAE port seal
58822
Tube assembly
58821
Tube assembly
C6226
Hydraulic filter head
C6227
Hydraulic oil filter
16145
Filter gauge
Air End & Assembly Replacement Components Part Number
Description
D1346
R30 Compressor air pump
7471
Valve assembly (Low pressure intake)
C0891
Valve assembly (Low pressure exhaust)
7472
Valve assembly (High pressure Intake)
C0894
Valve assembly (High pressure exhaust)
4558
Complete valve gasket set
4557
Complete valve set with / Gaskets
32895
Valve assembly kit (Includes both valves 7471 & 7472 only)
7417
Muffler assembly unloader
C0896
Release valve kit assembly
D1873
Intercooler tube w/Fittings (Right hand)
D1872
Intercooler tube w/Fittings (Left hand)
D0786
Cooler Mount Bracket (Left hand)
D0824
Cooler Mount Bracket (Right hand)
D0791
Coupling (Hydraulic motor)
D0792
Coupling (Compressor)
D0793
Lovejoy coupling (Blue urethane)
C0864
Air pressure switch
3853
Pilot valve 145/175 psi
5480
Check valve
D0840
Fan 12 volt
C5662
Metal filter bowl w/Filter
Service Component Replacement Parts Part Number
Description
4559
Air filter
6073
Intake filter assembly (Housing & filter)
C0087
Synthetic compressor oil (1 quart)
7259
Synthetic compressor oil (Case) 12 quarts
8825
Service kit (Includes air filters, compressor oil, hyd filter & filter bowl)
28
AE SHD66DD Owner’s Manual
Troubleshooting 29 29
Chapter 8: Troubleshooting If symptoms of poor performance develop, the following chart can be used as a guide to investigate and correct the problem. When diagnosing faults in operations of the air compressor, always check that the hydraulic power source is supplying the correct hydraulic flow and pressure that is listed in the compressor specification section of this manual. Problem
Possible Cause
Solution
Compressor will not start:
PTO not engaged.
Engage PTO.
Emergency brake off.
Fully engage parking brake.
Blown fuse.
Replace fuse.
Loose or broken power/ground wire.
Repair connection.
Compressor manifold solenoid will not Repair wiring to coil. Replace valve. engage. Compressor runs slow or slows down during operation:
Compressor will lock up after operating for a short period:
Loose air lines or hoses.
Tighten air lines and hose connections.
Hydraulic flow too low.
Check and reset flow.
Hydraulic motor worn.
Replace with new motor.
Hydraulic relief set too low.
Readjust relief valve.
Faulty compressor valves.
Clean or replace.
Pilot valve leaking air.
Replace pilot valve.
Centrifugal unloader valve leaking.
Remove the governor release valve cap, giving access to the unloader pressure release valve spring and ball - Clean thoroughly and reassembly.
Hydraulic oil temp high.
Hydraulic fluid low. Hydraulic reservoir size incorrect.
Hydraulic motor drive coupler loose.
Reposition and tighten coupler.
Faulty hydraulic relief valve.
Remove relief valve, inspect o-rings and backup seals or replace relief valve.
Faulty check valve.
Clean or replace check valve.
Dirty after cooler or intercooler tubing. Remove and clean. Compressor runs hot: Faulty compressor values.
Clean or replace valves.
Dirty intake muffler.
Clean or replace.
Low crankcase oil level.
Add compressor oil as needed.
30
AE SHD66DD Owner’s Manual
Problem
Possible Cause
Solution
Compressor will not shut down:
Air line or air hose leaks.
Tighten air lines or hose connections.
Misadjustment of pilot valve.
Adjust valve per manual specifications.
Pilot valve leaking air
Clean or replace pilot valve.
Centrifugal unloader valve is leaking.
See “Compressor runs slowly” section.
Moisture or rust contamination.
Remove filter bowl. Fill with WD40 lubricant. Open air tank valve. Run compressor for 10 minutes. Partially close air tank valve and cycle compressor. Repeat as needed.
Faulty low pressure intake valve.
Clean or replace low pressure intake valves.
Leaking or misadjustment of the pilot valve.
Tighten or adjust valve per manual specs.
Air reservoir full.
Drain air from reservoir.
Faulty pressure switch.
Test for 12 volt power on both the “C” and “NC” side of the terminals. If no power on “NC” side of pressure switch, replace switch.
No 12 volt power to coil solenoid valve located on hydraulic manifold.
Check fuse. Check ground wires. Check chassis emergency brake switch.
Loose wiring.
Check wiring to : Solenoid valve, pressure switch, ground wiring.
Faulty pressure switch.
Replace pressure switch.
Faulty speed control.
Check speed control wiring for loose or broken connections. Check relay (For ECM operated speed settings.)
Faulty pressure switch.
Replace pressure switch.
Excessive water in air reservoir.
Drain air reservoir.
Pip lines leaking air.
Tighten or replace lines.
Misadjustment of pilot valve.
Adjust valve per manual specifications.
Air leaking from pilot valve.
Clean, adjust, or replace.
Check valve leaking.
Clean or replace.
Compressor continues to build air during idle mode:
Compressor will not speed up when compressor is activated:
Engine RPM will not increase when compressor is activated:
Compressor cycles or runs often:
Faulty pressure switch. Chassis engine RPM continue to operate at high Pressure switch wiring. speed when air receiver reaches maximum capacity:
Replace pressure switch. Wires place on pressure switch incorrectly or loose ground wire.
31
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