Transcript
Model 45R
Rotary Screw Compressor Owner’s Manual Safety • Operation • Maintenance • Installation • Parts
Subject to Change without Notification. © 2015 American Eagle
American Eagle 740 North State Street PO Box 169 Garner, IA 50438 800-392-3015 www.americaneagleacc.com
Last Revision: 08/19/15
Model 45R Manual Revisions Date of Revision
Section Revised
Page ii | American Eagle® 45R Owner’s Manual
Description of Revision
Table of Contents Introduction.............................................................................................................................................iv Chapter 1 - Specifications.......................................................................................................................... v Chapter 2 - Operation................................................................................................................................ 1 General Operation................................................................................................................................. 1 Operator Requirements.......................................................................................................................... 1 Before Start-Up........................................................................................................................................ 2 Start-Up Procedure................................................................................................................................. 2 45R Air Operations.................................................................................................................................. 3 Safety Decals of Note............................................................................................................................. 3 Chapter 3 - Maintenance........................................................................................................................... 5 General Maintenance Guidelines........................................................................................................ 5 Service Intervals....................................................................................................................................... 6 Standard Maintenance Kit - PN 76913................................................................................................. 6 Oil Level.................................................................................................................................................... 7 Condensation Drain................................................................................................................................ 7 Changing the Oil..................................................................................................................................... 8 Oil Filter..................................................................................................................................................... 9 Separator Cartridge................................................................................................................................ 9 Air Filter................................................................................................................................................... 10 Minimum Pressure Valve....................................................................................................................... 10 Belt Tension............................................................................................................................................. 11 Hydraulic Oil Cooler/Compressor Oil Cooler..................................................................................... 12 Chapter 4 - Installation............................................................................................................................. 13 Component Installation........................................................................................................................ 13 45R Electrical Schematic...................................................................................................................... 14 Hydraulic System................................................................................................................................... 15 Air System............................................................................................................................................... 15 Compressor Pressure Switch................................................................................................................ 16 Typical Hydraulic Circuit for Single Stage Pump................................................................................ 17 Typical Hydraulic Circuit for Tandum (Two Part) Pump ................................................................... 18 Typical Hydraulic Circuit for Compressor with Auxiliary Cooler....................................................... 19 Chapter 5 - Assembly Drawings.............................................................................................................. 21 45R Case Assembly - PN 75582............................................................................................................ 21 45R Assembly Drawing - PN 76707...................................................................................................... 22 Chapter 6 - Troubleshooting..................................................................................................................... 25
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] American Eagle® 45R Owner’s Manual | Page iii
Introduction American Eagle® Air Compressors are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, these air compressors will operate at peak performance for many years. To promote this longevity, carefully study the information contained in this manual before putting the equipment into service. Though it is not intended to be a training manual for beginners, this manual should provide solid guidelines for the safe and proper usage of the air compressor. Once you feel comfortable with the material contained in this manual, strive to exercise your knowledge as you safely operate and maintain the air compressor. This process is vital to the proper use of the unit. A few notes on this manual: A copy of this manual is provided with every air compressor and can be found in the hard plastic manual case that is installed on the chassis. A copy of this manual shall remain with the air compressor at all times. Throughout the manual, three signal words will be used to bring attention to important items: NOTICE
A NOTICE signal word indicates a practice not related to physical injury.
A WARNING signal word indicates a hazardous situation which, if not WARNING avoided, could result in death or serious injury. DANGER
A DANGER signal word indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. Please be aware that some sections of this manual contain information pertaining to American Eagle® manufactured air compressors in general and may or may not apply to your specific model. 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. In closing: If more information is required or technical assistance is needed, or if you feel that any part of this manual is unclear or incorrect, please contact the American Eagle Customer Service Department by phone at 800-392-3015 or email at service@americaneagleacc. com. Page iv | American Eagle® 45R Owner’s Manual
Chapter 1 - Specifications
28.74”
23.16”
21.75”
31.03”
SPECIFICATIONS
45R
Hydraulic System
10-12 GPM
Compressor RPM
5500-6000 RPM
System Pressure
2800 PSI
Hydraulic Relief
3500 PSI
Max Air Pressure
150 PSI
Air Relief
200 PSI
Delivery (At Max Speed)
40-45 CFM @ 100 PSI
Weight
310 lbs.
Dimensions (Length)
29”
Dimensions (Width)
22”
Dimensions (Height)
26”
Electrical
12 VDC
Crankcase Oil Capacity
7 Quarts
Plumbing/Fittings
Steel W/JIC Fittings
Cooler Fan
2024 CFM, 12 Volt
Drive
Belt Drive
Manifold
6061 Aluminum
Control Valve
12 VDC Solenoid
American Eagle® 45R Owner’s Manual | Page v
Page vi | American Eagle® 45R Owner’s Manual
Chapter 2 - Operation Safety should be the number one thought on every operator’s mind. Three factors should exist for safe operation: a qualified operator, well-maintained equipment, and the proper use of this equipment. This chapter contains information regarding the safety and operation of American Eagle® manufactured air compressors and should be read and understood completely by everyone working with or near the air compressor before putting the unit into operation. WARNING Failure to follow operating, maintenance, or safety instructions can result in death or serious injury.
General Operation It is the responsibility of the owner to instruct the operator in the safe operation of the equipment and to provide the operator with properly maintained equipment.
WARNING American Eagle® Air Compressor operators must conform to the qualifications specified in this manual. Trainees or untrained persons shall be under the direct supervision of qualified persons. Operators shall consult with the owner of the equipment regarding current safety regulations and required personal protective equipment. Operators should never operate the air compressor while under the adverse influence of alcohol, drugs, or medication. Please take note that American Eagle is not liable for accidents incurred by the air compressor because of non-fulfillment from the operator’s side of current rules, laws, and regulations.
Operator Requirements Operation is limited to the following people: A. Qualified individual. B. Trainees under direct supervision of the qualified individual. C. Test or maintenance individual. D. Air compressor inspector. Qualified individuals must: A. D emonstrate the ability to understand all decals, the owner’s manual, and any other information required for safe operation of the air compressor. B. Be able to demonstrate the ability to safely control the air compressor. C. Know all safety regulations. D. Be responsible for maintenance requirements. E. Understand and be fully capable of implementing all emergency procedures. F. Understand all operating procedures as outlined by this manual. American Eagle® 45R Owner’s Manual | Page 1
Before Start-Up Inspect unit for any visible signs of damage. Check hoses (air and hydraulic) for weak or worn condition and make sure that all connections are secure.
WARNING Do not operate the compressor if it is damaged, improperly adjusted or not assembled properly. WARNING Do not operate the compressor with any of the guards removed. Check the oil level in the compressor (See Section “Changing the Oil”). If oil is needed, use American Eagle® Synthetic Compressor Oil (P/N C0087) or an equivalent synthetic oil. Check the air intake filter to make certain that it is clean and unobstructed. A dirty air filter is a possible cause of reduced air output.
WARNING The air taken in by the air compressor must be free of flammable fumes and vapors.
Start-Up Procedure To use the compressor: 1. Start the vehicle engine and engage the hydraulic system. 2. 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. The system will now function automatically.
WARNING Never use the compressor as a booster pump and/or to compress a medium other than atmospheric air. 3. Once engaged, adjust the engine speed control to ensure that the compressor speed does not exceed 8000 rpm under load. Adjustment instructions are provided with the speed control unit.
Page 2 | American Eagle® 45R Owner’s Manual
45R Air Operations Activating the compressor switch sends power to the cooling fan, hydraulic solenoid valve and normally closed terminal (87A) on the Bosch relay. The normally open hydraulic solenoid valve closes, sending hydraulic oil to the motor operating the compressor. The fan and compressor operate whenever the hydraulic system is engaged and the compressor switch is on. Power from the common terminal (30) on the Bosch relay goes to the line terminals on the compressor pressure switch. If the air pressure is below the kick out pressure (115 psi minimum/120 psi maximum) the pressure switch closes sending power to the engine speed control and compressor air inlet solenoid valve. The engine speeds up and the compressor begins pumping air. When the air pressure reaches the kick out pressure setting (145 psi minimum/150 psi maximum) the pressure switch opens, shutting the air inlet valve and deactivating the speed control. The compressor is protected by an air pressure and compressor oil switch gauge. The coil on the Bosch relay is grounded through these two switch gauges. If the air pressure or compressor oil temperature exceeds the switch gauge settings they close, completing the circuit and energizing the relay coil. The normally closed switch on the Bosch relay opens cutting power to the compressor pressure switch. The compressor stops pumping air and the engine slows down. The switch gauges are set at the factory and should not be adjusted.
Safety Decals of Note Safety decals serve to inform the viewer of the hazard type, how to avoid the hazard, and the consequences of not avoiding the hazard. Decals are considered safety equipment. They must be maintained, as would other safety devices. All safety instruction plates, notices, load charts and any other decal applied to the air compressor or vehicle must be kept legible and in good condition. Replace any decals that are missing, damaged, or illegible.
WARNING Untrained Operator Hazard Read and understand all manuals and safety signs before operating or servicing this equipment.
Breathing Hazard
Do not use air from compressor for breathing or food processing.
Fluid Hazard Do not search for leaks with hands or other body parts. Relieve pressure before disconnecting lines. Tighten all connections before applying pressure.
Failure to obey the following can result in death or serious injury:
Burn Hazard
Do not touch any internal surfaces during or shortly after operation.
Crush Hazard
Keep clear while unit is in operation.
Do not operate unit without cover attached.
Pressure Hazard Do not remove caps, plugs, or other components while unit is running or has pressure in tank. Disconnect power and relieve all pressure prior to maintenance.
American Eagle® 45R Owner’s Manual | Page 3
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Page 4 | American Eagle® 45R Owner’s Manual
Chapter 3 - Maintenance Maintenance is an important part of extending the life of any American Eagle® Air Compressor. Performing key maintenance items on a scheduled program will prevent unnecessary downtime.
General Maintenance Guidelines Before performing any maintenance to the air compressor, consider the following:
WARNING Only qualified service personnel are to perform maintenance on the • Air compressor. Never modify or alter any of the equipment, whether mechanical, electrical, or hydraulic, without explicit approval from American Eagle. • Shut off the engine and disengage the PTO. •P lace all controls in the off position and secure operating features from inadvertent motion. • Disable all power to the air compressor and remove any stored energy. • 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.
WARNING Do not disconnect hydraulic hoses while there is still pressure in those • components. WARNING Do not touch the air compressor or plumbing until the unit has cooled • down. The surface of the air compressor and the plumbing between the compressor and the cooler may reach temperatures above 150 degrees. •R eplace parts with American Eagle® approved parts only. •K eep the air compressor clean and free from grease build-up, oil and dirt to prevent slippery conditions. • L abel or tag parts when disassembling. • Immediately repair or have repaired any components found to be inadequate. • Always connect hoses to the compressor before energizing the power source. Be sure all hose connections are tight.
NOTICE • Do not attempt to adjust or disable the compressors air pressure relief valve. This valve protects the compressor in the event of blockage or air control system malfunction.
American Eagle® 45R Owner’s Manual | Page 5
Service Intervals 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, turn off compressor, hydraulic system, truck engine and remove keys to assure that compressor is not started. Be sure all air pressure in unit is relieved. Failure to do so may result in injury or equipment damage. Maintenance Schedule
Daily
Weekly
Monthly
Hourly
Drain air tanks. Check compressor case oil level. Check fittings and airlines. Check hydraulic fluid level. Inspect and clean air intake filters.
100
Check oil cooler. Clean as needed. Replace coalescering/separator cartridge.
12
3000
Change compressor oil and oil filter.
6
1000
Replace hydraulic filter.
6
Replace air filter.
3
Tighten all fittings and fasteners.
3
Check all electrical connections.
3
100
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. USE AE SYNTHETIC COMPRESSOR OIL P/N C0087. COMPRESSOR CRANKCASE CAPACITY IS 7 QUARTS.
Standard Maintenance Kit - PN 76913 This service kit includes, oil filter, separator filter, air filter, and 7 quarts of oil. To order, please contact the American Eagle Customer Service Department by phone at 800-392-3015 or email at
[email protected].
Page 6 | American Eagle® 45R Owner’s Manual
Oil Level The oil level in the compressor case is an important factor for the operational reliability of the system. Check Intervals: 1. Before starting unit. 2. Every 100 operating hours
OIL RECOVERY VIEWER
Check Procedures: MAX OIL 1. Turn off the compressor, hydraulic system and truck LEVEL engine to ensure that compressor is not started. 2. Wait for one full minute. 3. Slowly unscrew the oil fill cap on the compressor case (also referred to as the separator receiver). 4. Check the oil level. 5. If the oil level is under the minimum level, add oil to maximum level as shown. 6. Replace cap and hand tighten. Unit is ready to be put into service. Note: The screw-type oil fill cap is has a bleed hole which will release pressure in the compressor case. The bleed hole is exposed after the cap is loosened about two turns. If there is still pressure in the case, wait a few minutes for it to bleed off.
Condensation Drain Condensation (water) in the oil affects the operation and life of the screw compressor. Screw compressors are especially vulnerable due to the fact that the oil is used for both sealing and lubrication. Both oil and water are removed from the air in the separator cartridge and returned to the compressor case. Condensation builds up faster when the compressor is operated intermittently in humid conditions. Under these conditions, the condensate should be drained each day before start up when the compressor is cold. Possible Malfunctions: Insufficient lubrication. Poor air/oil separation and high pressure across the separator cartridge. Corrosion and rust formation. Maintenance Procedure 1. Unscrew oil fill cap. 2. Place a container under the oil drain pipe and carefully unscrew the oil drain cap. 3. Drain the water from the compressor case until nothing but oil comes out, replace the cap and tighten. 4. Fill the compressor case with oil to maximum and replace oil fill cap. 5. Turn on compressor and operate for three minutes. 6. Check oil level and fill if low. 7. Dispose of condensate (mixture on water and oil) in accordance with local and federal regulations. American Eagle® 45R Owner’s Manual | Page 7
Changing the Oil Change the oil with the compressor at operating temperature of 140-175 degrees F (60-80 degrees C).
WARNING Compressor must be stopped and all air receivers discharged before changing oil. Compressor oil is hot and can cause burns. 1. Turn off the compressor, hydraulic Pressure system and truck engine to ensure that Line compressor is not started. 2. Discharge air receiver. Air Delivery 3. Wait for one full minute. 4. Slowly unscrew the oil fill cap on the compressor case. Return 5. Place a container under the oil drain Line pipe and carefully unscrew the oil drain cap. 6. Drain the oil from the compressor case, then replace and tighten oil drain cap. 7. Refill with oil to maximum level and replace oil fill cap. Oil capacity is 7 quarts. 8. Operate compressor for 3 minutes. 9. Check oil and fill to maximum if necessary.
Oil Recommendations
Oil Requirements
Screw compressors must be operated using the most suitable oil for operation. The compressor manufacturer must approve this oil for use. The oil must also be suitable for use in unfavorable conditions such as: contamination of the intake air by gases, solvent vapors, exhaust gases, and high ambient temperature conditions.
High aging stability
Suitable types and brands of oil may be specified on request. Suitable screw compressor oils can be mineral oils, synthetic oils, and biological degradable oils.
Pour-point: 5° below lowest ambient temperature minimum
The substances and materials used in the compressor such as seals must be taken into account when selecting the types of oil. Corrosion or other material degradation must not occur.
High corrosion protection
NOTICE
High disperse capacity Low emulsification tendency Flash point: above 400°F/ 200°C
Minimum foaming
Hydraulic or turbine oil Basic oil: solvate
Do not mix different types of oil.
NOTICE In the case of ambient temperatures close to freezing, prevent the unit from freezing. Pipeline Materials: The oil used in screw compressors can degrade plastics used in air pipelines.
Operating temperature: up to 230°F / 110°C Viscosity class: ISO 46 or ISO VG 68 Viscosity at 104°F / 40°C: ca. 42-50 mm2/s (cST)
Page 8 | American Eagle® 45R Owner’s Manual
Oil Filter The oil filter is located to the front of the unit. When viewing the unit from the oil fill cap end, the oil filter will be to the left front. It is necessary to remove the side panel to access the oil filter. Replace the filter after the first 50 hours of service and every 1,000 hours or every 6 months, whichever comes first. Maintenance Procedure 1. Turn off the compressor, hydraulic system and truck engine to ensure that compressor is not started. 2. Slowly unscrew and remove the oil filter with an oil filter wrench. 3. Grease the new filter gasket. 4. Before installing, hold the new filter upright and fill it with the same oil as used in the compressor case. 5. Screw the new filter onto the compressor. Hand tighten, do not use a filter wrench. Turn approximately 3/4 turn after gasket contacts the compressor. 6. Run compressor for 3 minutes. 7. Check oil level and fill if necessary.
OIL FILTER P/N 76369
Separator Cartridge The separator cartridge is disposable and is located on top of the filter support. The cartridge has to be replaced at least once per year and at a maximum of 3000 operating hours. If intake air is often contaminated or the oil quality is poor, the cartridge will tend to clog earlier and will need to be changed more often. Maintenance Procedure: 1. Turn off the compressor, hydraulic system and SEPARATOR truck engine to ensure that compressor is not FILTER started. P/N 76583 2. Slowly unscrew and remove cartridge with an oil filter wrench. 3. Screw the new cartridge onto the filter support. Hand tighten, do not use a filter wrench. Turn approximately 3/4 turn after gasket contacts the compressor. 4 Write the date of change and operating hours on cartridge. 5. Run compressor for 3 minutes. 6. Check cartridge to ensure that it is tight. American Eagle® 45R Owner’s Manual | Page 9
Air Filter The air filter should be changed every 100 hours of operation. The filter may require changing or cleaning more frequently if the compressor is operated in a dusty environment. Maintenance Procedure: 1. Turn off the compressor, hydraulic system and truck engine to ensure that compressor is not started. 2. Open filter lid and carefully remove filter. 3. Carefully remove dust from the intake housing. 4. Clean and install or install new filter: • Clean filter be tapping outside of filter on a hard surface. •Clean filter with compressed air by blowing from the inside to the outside. Limit air pressure to 75 psi. 5. Close filter lid. 6. Test run compressor.
AIR FILTER P/N 76582
AIR FILTER P/N 76582
NOTICE Any dirt or debris that enters the compressor intake when the air filter is removed can cause irreversible damage.
LOCK NUT
Minimum Pressure Valve The minimum pressure valve is set at the factory. If oil blows out through the air filter the minimum pressure valve OIL FILTER may need P/N to be set. 76369
A
ADJUSTING SCREW
Minimum Pressure Valve Set Procedure 1. Remove the lock nut. 2. Turn the adjusting screw in until it just LOCK NUT touches. 3. Turn the adjusting screw out three full turns. ADJUSTING SCREW 4. Replace and tighten lock nut. OIL FILTER P/N 76369
Page 10 | American Eagle® 45R Owner’s Manual
A
Belt Tension
SPAN BELT DEFLECTION
FORCE APPLIED
New Belt Installation Tension: 98.0 lbf Tensioning Force: 6.8 lbf Belt Deflection: 9/64 in Span Length: 9.00 in
Used Belt Installation Tension: 65.4 lbf Tensioning Force: 4.8 lbf Belt Deflection: 9/64 in Span Length: 9.00 in
American Eagle® 45R Owner’s Manual | Page 11
Hydraulic Oil Cooler/Compressor Oil Cooler For reliable operation and longevity of both compressor and hydraulic system, the cooler should be kept clean. The compressor system is protected from operation at high temperature by a switch gauge. If the compressor shuts down or is operating close to the shut down temperature, the cooler should be cleaned. The cooler can be cleaned with compressed air, pressure washer or steam cleaner. Maintenance Procedure 1. Turn off the compressor, hydraulic system and truck engine to ensure that compressor is not started. 2. Discharge the receiver. 3. Remove the shroud. 4. Drain oil from the compressor. 5. Disconnect: a. Lines to the cooler. b. Lines to the thermo valve. c. Electrical connection to the fan. 6. Remove the cooler. 7. Remove the fan shroud and fan from the cooler. 8. Cap the hydraulic fittings on the cooler and thermo valve. 9. Clean cooler. 10. Reinstall the cooler in reverse order. 11. Refill with oil. 12. Test run compressor and check operating temperature. 13. Check oil level and fill if necessary.
Page 12 | American Eagle® 45R Owner’s Manual
Oil Cooler
Chapter 4 - 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. Note: A dual or tandem hydraulic pump is recommended when additional hydraulically operated equipment are added to the hydraulic system. PTO Assembly: Check with the PTO manufacturer’s 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 ensure proper installation of the PTO. Compressor Assembly: Prepare the mounting location of the compressor by locating and drilling four (4) holes, 1/2” diameter as per the mounting pattern of the air compressor base. Using four (4) 3/8” x 1.25 GR-5 cap screws, 3/8” flat washer, and 3/8” 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 preset speed when engaged and decrease when disengaged.
ELECTRICAL PIGTAIL (STELLAR SUPPLIED)
CIRCUIT BREAKER (STELLAR SUPPLIED) BATTERY +
POWER SUPPLY (12V BATTERY HOT) CPRSR RELAY (12V CONTROL INPUT)
* CUSTOMER ADDED WIRING MUST MATCH OR EXCEED PIGTAIL WIRE SIZE FOR POWER SUPPLY AND GROUND CIRCUIT
SPEED CTRL (12V CONTROL OUTPUT) GROUND
RED 12GA
GRN 14GA
YEL 14GA
BLK 12GA
American Eagle® 45R Owner’s Manual | Page 13
45R Electrical Schematic Electrical Connections: From the air pressure switch there are two (2) wires, red and black, running to the outside of the compressor housing. Connect the black wire to the vehicle frame or other suitable ground. Mount a single throw toggle switch in a convenient location and connect the red wire from the compressor to this switch. Connect the other switch terminal to a fuse holder and then to a 12- volt power supply. A third wire is required from the air compressor switch when connecting the speed control into the system.
PN 76364
Page 14 | American Eagle® 45R Owner’s Manual
Hydraulic System The hydraulic system consists of the pump, oil reservoir, filters and hoses. 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 pressure side of the hydraulic pump. A 3/4” minimum low-pressure return line is connected to the oil cooler outlet and is routed to the oil reservoir. American Eagle recommends a sufficient sized reservoir be provided that includes the proper suction and return filters. The cooler on the compressor is designed and sized to cool the air compressor efficiently. An auxiliary 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.
Air System The airline is routed using a 3/4” (200 psi) air hose. This delivery line should be free from all obstructions. Note: There should be no check valve installed between the compressor and the air tank. American Eagle recommends the installation of a ten gallon air tank (minimum) to maintain proper operation of the air compressor.
Pressure Line Air Delivery Return Line American Eagle® 45R Owner’s Manual | Page 15
Compressor Pressure Switch
Kick Out (Step 1) Pressure Setting Adjustment Screw (145-150 psi)
Kick On (Step 2) Pressure Setting Adjustment Screw (115-120 psi)
Pressure Switch
Note: Turning adjustment screws clockwise increases psi settings. Turning adjustment screws counterclockwise decreased psi settings.
Pressure Setting Instructions: 1. Always set the kick out pressure setting first. Adjust the kick out screw setting to 145 psi minimum/150 psi maximum. 2. After kick out pressure is set, adjust the kick on screw setting to 115 psi minimum/120 psi maximum. 3. Cycle compressor to verify correct settings. 4. For questions about this procedure, please contact Stellar Customer Service at 800-321-3741.
Page 16 | American Eagle® 45R Owner’s Manual
PN 30533
Typical Hydraulic Circuit for Single Stage Pump
American Eagle® 45R Owner’s Manual | Page 17
Typical Hydraulic Circuit for Tandum (Two Part) Pump
Page 18 | American Eagle® 45R Owner’s Manual
Typical Hydraulic Circuit for Compressor with Auxiliary Cooler
HYDRAULIC RESERVOIR
FILTER SCREEN
FILTER
AUXILIARY COOLER SUCTION PORT
SINGLE HYDRAULIC PUMP
COMPRESSOR RETURN
PRESSURE
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Chapter 5 - Assembly Drawings 45R Case Assembly - PN 75582 12
14
15 9
13
4
6
18
16
17 5
16
11
18
18
16
18
16
15
2
16 18
8
15 9 3
1 10
15 9
PN 75582 ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
PART 75583 75586 75584 75585 69103 73654 70379 70379 19592 19589 73653 69101 75877 75587 C6021 0333 0342 D0917
DESCRIPTION QTY. PANEL FRONT CPRSR HR-65 SHROUD PC WHITE 1 PANEL BACK CPRSR HR-65 SHROUD PC WHITE 1 PANEL SIDE RH HR-65 SHROUD PC WHITE 1 PANEL SIDE LH HR-65 SHROUD PC WHITE 1 GAS SPRING 7.50-12.00 30# FORCE 1 BRKT LID GASPROP CPRSR SHROUD V2 PC WHITE 1 HINGE ZINC BLK FLUSH SURFACE MNT DC-50-P8 1 HINGE ZINC BLK FLUSH SURFACE MNT DC-50-P8 1 WASHER 0.25 FLAT NYLON 15 NUT SERT 0.25-20X0.38 OD 12 BRKT LOWER GASPROP CPRSR SHROUD V2 PC WHITE 1 LATCH SWING LEVER FLUSH TRIGGER 0.91-1.81 1 WEATHERSTRIP RIBBED 0.38X0.13X98.00 1 PANEL LID CPRSR HR-65 SHROUD PC WHITE 1 CAP SCR 0.25-20X0.75 BTNHD SS 17 NUT 0.25-20 HHGR5 NYLOC 13 NUT 0.31-18 HHGR5 NYLOC 2 WASHER 0.25 FLAT SS 13
American Eagle® 45R Owner’s Manual | Page 21
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13
14
34
39
39
33
30
55
73
56
43 11
12
31
34
15
26
9
41
8
10
54
22
42
8
46 45
49
1
57
21
58
51
53
59
47
48
29
50
28
70
52
72
61
2
60
77
62
25
24
40
67
19
7
66
17
6
27
38
31
73
75
76
32
73
65
34
69
16
5
64
68
73
33
35 4
45R Assembly Drawing - PN 76707
17
71
23
44
18
36
20
73
74 37
63
73
37
17
18 3
American Eagle® 45R Owner’s Manual | Page 23
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 34 35 36 37 38 39
PART 75580 75875 76503 76586 34541 34538 77396 65586 75582 75588 21650 28855 D1318 21393 65025 70472 C2142 1554 c4903 75591 75592 75592 21651 75871 75874 76363 C0082 D1307 0525 0479 0521 77397 19589 C6021 5735 0420 0522 C2269 19592
DESCRIPTION BASE WLDMT HR-65 PC BLACK CPRSR V76 AIREND VMC COOLER OIL SRS65 W/SHROUD MNT SHROUD SRS65 FAN MNT W/AKG CLR W/SIDE MNT FAN 16.00 PULL 12 VOLT 30102049 SPROKET GOODYEAR EAGLE PD Y-36S-H BUSHING SH X 28MM FTG 6-6 MFS-MBSPP 90 SHROUD ASM HR-65 CPRSR PANEL BULKHEAD HR-65 CPRSR PC WHITE GAUGE OIL TEMP TSB20TVD3006125SR240 HOUR METER 12VDC TST 180-1911 FTG 8-8 MFS-MFS BULKHEAD UNION FTG 12-12 FP-MJ BULKHEAD STRAIGHT FTG 12-12 MFS-MFS BULKHEAD UNION MANIFOLD ASM SVRV10-12SAE 3500PSI ALUM BODY FTG 12-12 MFS-MORB STRAIGHT FTG 8-8 MFS-MORB STRAIGHT FTG 12-12 MFS-FFSS 90 HOSE 0.75(200PSI)-12FFSS SHORT-12FFSS SHORT-18.50CL HOSE 0.38(3000PSI)-8FFSS SHORT-6FFSS SHORT-27CL HOSE 0.38(3000PSI)-8FFSS SHORT-6FFSS SHORT-27CL BELT GOODYEAR EAGLE PD Y-896 HOSE 0.50(3000PSI)-8FFSS SHORT-8FFSS 90 SHORT-30CL HOSE 0.75(3000PSI)-12FFSS SHORT-12FFSS 90 SHORT-16CL FTG 12-8 FP-MBSPP CLAMP 0.75 BLK VINYL CAP SCR 0.50-13X1.25 SH WASHER 0.50 LOCK CAP SCR 0.25-20X0.75 HHGR5 WASHER 0.25 LOCK MOTOR HYD 20.14D0-49S1-LOC/OD-N-EL-C NUT SERT 0.25-20X0.38 OD CAP SCR 0.25-20X0.75 BTNHD SS NUT SERT 0.31-18X0.50 OD CAP SCR 0.31-18X0.75 HHGR5 WASHER 0.31 LOCK FTG 12-16 MFS-MORB STRAIGHT WASHER 0.25 FLAT NYLON
QTY. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 4 4 2 6 1 6 12 4 4 6 1 8
ITEM 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 65 66 67 68 69 70 71 72 73 74 75 76 77 78
PART 22162 22183 22186 18611 D0525 6390 C5576 76360 C0863 73652 C5616 76369 76582 76583 C6379 3864 76367 13580 70539 13579 76585 76704 76708 78008 21655 76709 76710 C2252 C0944 0347 76714 76716 75874 41047 C0922 0523 0351 76717 9586
DESCRIPTION CAP SCR 8MMX25MM SH SCREW #8-32X0.75 BTNHD SS NUT #8-32 HH NYLOC SS SCREW #6-32X0.38 HH MACH SELF TAP FTG 12-12-12 MFS-FFSS-MFS RUN TEE FTG 2-4 MP-FP STRAIGHT EXPANDER FTG 4-4 MP-MP HEX NIPPLE FTG 4-4 MP-FPS 90 SWITCH PRES COMPRESSOR PLUG NICKEL PLATED BUTTON 0.88 CLAMP ROMEX 0.50 FILTER OIL HR-65 FILTER AIR HR-65 FILTER SEPERATOR HR-65 FTG 12-12 MJ-FJS 90 FTG 12-12 MJ-MP 90 HOSE STEAM 0.75-12FJS SHORT-12FJS SHORT-4.5CL STST FTG 8-8 FP-FP 90 BRASS PLUG 0.50 NPT SQ HD BRASS FTG 8-8X2.50 MP-MP NIPPLE STRAIGHT BRASS FTG TEMP PROBE MOD HR-65 HOSE AIR INTAKE HR-65 3"CL BRKT MOTOR MOUNT HR-45 BRKT COOLER 45R/65R PC BLACK BUSHING 0.75 SDS FTG 10-10-10 MAORB-FORB-FORB TEE FTG 12-10 MAORB-ORB STRAIGHT FTG 8-10 MFS-MORB STRAIGHT CAP SCR 0.38-16X1.75 HHGR5 NUT 0.38-16 HHGR5 NYLOC HOSE CLAMP 2.16-2.31IDX0.78 SPROKET GOODYEAR PD Y-63S-SDS HOSE 0.75(3000PSI)-12FFSS SHORT-12FFSS 90 SHORT-16CL WASHER 0.25 BONDED SEALING NEO BACK CAP SCR 0.31-18X1.00 HHGR5 WASHER 0.38 LOCK CAP SCR 0.38-16X1.00 HHGR5 BRKT LIFTING BAR HR-45/65 PC BLACK OIL SYNTHETIC CPRSR BULK
45R Assembly Bill - PN 76707 QTY. 4 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 13 2 1 1 1 7 qt
Page 24 | American Eagle® 45R Owner’s Manual
Chapter 6 - 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. As always, feel free to contact American Eagle® Customer Service at 1-800-321-3741 Problem
Possible Cause Compressor temperature. Low oil level. Fan not operating. Plugged oil filter. Compressor Shuts Down with air Dirty cooler core. demand: Contaminated cooler core. Hydraulic pressure and flow incorrect Worn hydraulic motor.
Compressor will not build up pressure:
Compressor over pressures:
Compressor noisy or loud when starting compressor in cold weather: Compressor synthetic oil has a milky appearance:
Adjust and reset according to specifications. Replace.
Air demand too great.
Tighten air hose clamps. Repair air leaks.
Air filter plugged. Pressure switch out of adjustment. Faulty pressure switch. Compressor speed too slow. Drive belt slipping. Service valve wide open. Solenoid valve on. Hydraulic Manifold valve stuck (closed). Defective pressure switch. Air control line leaking. Inlet valve stuck. Restriction in control line (dirt/ice). Belt Slipping
Clean or replace.
Insufficient hydraulic system pressure or flow.*
Compressor Stalls:
Solution Clean Cooler Fin Add compressor oil to level. Check ground wire and fan switch/relay. Replace filter. Clean cooler fins. Remove and clean.
Presssure relief set too low. Pressure relief seals leaking. Air pressure set too high for hydraulic system. Solenoid valve cartridge seals leaking on hydraulic manifold assembly. Hydraulic reservoir low on oil. Ice buildup inside compressor from condensation
Readjust to specifications. Replace. Check hydraulic flow and pressure. Readjust and tighten. Close valve. Clean or replace. Replace. Check and correct. Clean and replace. Clean and free up. Readjust and tighten. Check the following: 1. Setting on supply pressure sytem relief valve. 2. Ensure adequate pressure and flow. 3. Check and see if other hydraulic systems activated off the same hydraulic supply. Readjust. Replace. Adjust pressure switch to reduce air pressure. Replace with new cartridge. Add to oil level. Engage PTO and allow hydraulic fluid to circulate and warm system up before engaging compressor.
Coalescering/Separator Replace cartridge and change compressor oil. cartridge clogged or plugged. Replace cooler, change filters and compressor Ecessive oil level in compressor: Internal crack inside oil cooler. oil.
*This can occur if another hydraulically activated component is used off the same pump system. Activating the secondary component may drop hydraulic supply system pressure/flow and leave insufficient for compressor. Not: Even a momentary drop in hydraulic supply pressure or flow may initiate compressor blowdown to commence.
American Eagle® 45R Owner’s Manual | Page 25
Page 26 | American Eagle® 45R Owner’s Manual
