model rs60ac air compressor operators, maintenance...
TRANSCRIPT
MODEL RS60ACAIR COMPRESSOR
OPERATORS, MAINTENANCEAND PARTS MANUAL
P/N: 30719911/28/11 MCM
4
OPERATORS, MAINTENANCE, AND PARTS MANUALAUTO CRANE MODEL RS60AC
Operation & Maintenance Section
TABLE OF CONTENTS
Operation & Maintenance Section
Specifications ...................................................................................................................... 6
Safety .................................................................................................................................. 7
Compressor Terminology .................................................................................................. 11
Description of Components............................................................................................... 12
Inspection, Lubrication, and Maintenance .......................................................................... 16
Troubleshooting ................................................................................................................. 24
Compressor Operation ...................................................................................................... 27
Parts and Illustration Section ............................................................................................. 29
Recommended Spare Parts ................................................................................................ 36
Service Questionnaire........................................................................................................ 37
Instructional Procedures for Installation ........................................................................... 38
6
SPECIFICATIONS
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Parts ListDESCRIPTIONPART NUMBERQTYITEM
COMPR MTG SYS, RS60AC 45/60/150 SCI8G20035911ELEC SYS, RS60AC 45-60-150 SCI8G20035812OIL-AIR-HYD CLNG SYS, RS60AC SCI8G20036013CANOPY SYS, RS60AC 45-60-150 SCI8G20035714OPT, RS60 SHIPPING MATERIALS612841NSKIT, HOSE INFINITY800991NS
SHEET
20067-0011 1 OF
REV14
RS60AC 45-60 SCIG
AUTO CRANEP.O. BOX 580697
TULSA, OK 74158-0697
N/APATH
MATERIAL
G:\Inventor Files\20k\20067-001.dwg
12/3/2007
12/3/2007DCLDRAWN
NDDCHECKED
1=4D
DESCRIPTION
DWG NOSCALESIZE
UNMACHINED SURFACES
FRACTIONAL ` 1/16
DECIMAL .03
ANGULAR ` 1°
DO NOT SCALETOLERANCES
UNLESS NOTED
MACHINED SURFACES NOMINAL DIM.
0.000 TO 1.000 .010
1.001 TO 5.000 .015
5.001 TO 10.000 `.020
10.001 & OVER `.025
THIS DRAWING AND ALL INFORMATION THEREIN ISTHE PROPERTY OF AUTO CRANE, IS CONFIDENTIAL AND MUST NOT BE MADE PUBLIC OR COPIED. IT IS LOANED SUBJECT TO RETURN UPON DEMAND, IS NOT TO BE USED DIRECTLY OR INDIRECTLYIN ANYWAY DETRIMENTALTO THE INTEREST OF AUTO CRANE.
PROPRIETARY INFORMATION
34 3/4 in[882.7 mm]
32 1/4 in[819.2 mm]
17 3/4 in[450.9 mm]
6 3/8 in[163.2 mm]
5 in[127.0 mm]
19 in[481.4 mm]
20 1/4 in[514.4 mm]
DIMENSIONS OF MOUNTING HOLES
14 UPDATED 200359 TO REV 9. 3/10/2011 MCM13 UPDATED 200359 TO REV 8. 1/28/2011 MCM12 UPDATED 200357 TO REV 2. 1/25/2011 MCM11 UPDATED 200359 TO REV 7. 11/18/2010 DCL10 UPDATED 200359 TO REV 6. 11/8/2010 MCM9 UPDATED 200359 TO REV 5. 9/21/2010 MCM8 UPDATED 200359 TO REV 4. 6/16/2010 MCM7 UPDATED 200359 TO REV 3. 4/8/2010 DCL6 UPDATED 61284 TO REV 2. 2/10/2010 MCM
REVISION HISTORYREV DESCRIPTION DATE ENG
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WARNING
AIR COMPRESSOR SAFETY PRECAUTIONS
Safety is basically common sense. While there are standard safety rules, each situation has its ownpeculiarities that cannot always be covered by rules. Therefore with your experience and commonsense, you are in a position to ensure your safety. Lack of attention to safety can result in:accidents, personal injury, reduction of efficiency and worst of all - Loss of Life. Watch for safetyhazards. Correct them promptly. Use the following safety precautions as a general guide to safeoperation:
Do not attempt to remove any compressor parts without first relieving the entire system ofpressure.
Do not attempt to service any part while machine is operating.
DANGER
Do not operate the compressor at pressure(s) or speed in excess of its rating as indicated in“Compressor Specifications”.
Periodically check all safety devices for proper operation.
Do not play with compressed air. Pressurized air can cause serious injury to personnel.
Exercise cleanliness during maintenance and when making repairs by covering parts and exposedopenings.
SAFETY
ALL UNITS ARE SHIPPED WITH A DETAILED OPERATORS AND PARTSMANUAL. THIS MANUAL CONTAINS VITAL INFORMATION FOR THE SAFEUSE AND EFFICIENT OPERATION OF THIS UNIT. CAREFULLY READTHE OPERATORS MANUAL BEFORE STARTING THE UNIT. FAILURE TOADHERE TO THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILYINJURY OR PROPERTY DAMAGE.
CHECK THE COMPRESSOR SUMP OIL LEVEL ONLY WHEN THE COMPRESSORIS NOT OPERATING AND SYSTEM IS COMPLETELY RELIEVED OF PRESSURE.OPEN SERVICE VALVE TO ENSURE RELIEF OF SYSTEM AIR PRESSURE WHENPERFORMING MAINTENANCE ON COMPRESSOR AIR/OIL SYSTEM. FAILURETO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTYAND SERIOUS BODILY HARM.
8
SAFETY
Do not install a shut-off valve between the compressor and compressor oil sump.
DANGE�
Do not disconnect or bypass safety circuit system.
Do not install safety devices other than authorized AUTO CRANE replacement devices.
Close all openings and replace all covers and guards before operating compressor unit.
Tools, rags, or loose parts must not be left on the compressor or drive parts.
Do not use flammable solvents for cleaning parts. This can cause the unit to ignite during operation.
Keep combustibles out of and away from the Compressor/Inlet and any associated enclosures.
The owner, lessor, or operator of the Compressor are hereby notified and forewarned that any
failure to observe these safety precautions may result in damage or injury.
AUTO CRANE expressly disclaims responsibility or liability for any injury or damage caused by
failure to observe these specified precautions or by failure to exercise that ordinary caution and
due care required when operating or handling the Compressor, even though not expressly specified
above.
DO NOT USE AUTO CRANE COMPRESSOR SYSTEMS TO PROVIDE BREATHINGAIR. SUCH USAGE, WHETHER SUPPLIED IMMEDIATELY FROM THECOMPRESSOR SOURCE, OR SUPPLIED TO BREATHING TANKS FORSUBSEQUENT USE, CAN CAUSE SERIOUS BODILY INJURY.
AUTO CRANE DISCLAIMS ANY AND ALL LIABILITIES FOR DAMAGE FOR LOSSDUE TO PERSONAL INJURIES, INCLUDING DEATH, AND/OR PROPERTYDAMAGE INCLUDING CONSEQUENTIAL DAMAGES ARISING OUT OF ANYAUTO CRANE COMPRESSORS USED TO SUPPLY BREATHING AIR.
9
SAFETY
A compliment of warning decals is supplied with each unit. These decals must be affixed to thecomressor package in the locations noted in this manual. If for any reason a safety decal isremoved it is the owners responsibility to make sure it is replaced.
10
SAFETY
11
COMPRESSOR TERMINOLOGY
AIR/OIL COALESCER - Performs second stage separation of oil from compressed air feeding
air tools. Sometimes referred to as the separator element.
CFM - Refers to the volume of compressed air being produced, expressed as cubic feet of air per
minute.
COMPRESSOR LUBRICANT - DEXTRON III ATF.
GPM - Refers to the amount of gallons per minute of hydraulic fluid flowing through the pump.
OIL SUMP - The first stage of oil separation from compressed air. Also serves as reservoir area
for compressor lubricant and sometimes referred to as the receiver tank.
PSI - Refers to the operating pressure the system is set up at, expressed as pounds per square
inch.
SAFETY VALVE - A valve located on the oil sump which opens in case of excessive pressure.
Sometimes referred to as the pop-off or pressure relief valve.
12
DESCRIPTION OF COMPONENTS
COMPRESSOR ASSEMBLY
The AUTO CRANE hydraulic drive compressor assembly is a positive displacement, oil flooded,
rotary screw type unit employing one stage of compression to achieve the desired pressure.
Components include a housing (stator), two screws (rotors), bearings, and bearing supports.
Power from the hydraulic motor shaft is transferred to the male rotor through a drive coupling.
The female rotor is driven by the male rotor. There are five lobes on the male rotor while the
female rotor has six roots.
PRINCIPLES OF OPERATION
In operation, two helical grooved rotors mesh to compress air. Inlet air is trapped as the male
lobes roll down the female grooves, pushing trapped air along, compressing it until it reaches the
discharge port in the end of the stator and delivers smooth-flowing, pulse-free air to the receiver.
During the compression cycle, oil is injected into the compressor and serves these purposes:
1. Lubricates the rotating parts and bearings.
2. Serves as a cooling agent for the compressed air.
3. Seals the running clearances.
LUBRICATION SYSTEM
Oil from the compressor at discharge pressure, is directed into its integral housing, through the
thermal valve and filter, and then out of the integral housing to the oil cooling system, and then back
to the side of the compressor stator, where it is injected into the compressor. At the same time oil
is directed internally to the bearings and shaft seal of the compressor.
OIL SUMP
Compressed, oil-laden air enters the sump from the compressor. As the oil-laden air enters the
sump, most of the oil is separated from the air as it passes through a series of baffles and diffusion
plates. The oil accumulates at the bottom of the sump for recirculation. However, some small
droplets of oil remain suspended in the air and are passed on to the Coalescer.
SAFETY VALVE
The pop safety valve is set at 200 PSI and is located at the top of the air/oil sump. This valve acts
as a backup to protect the system from excessive pressure that might result from a malfunction.
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DESCRIPTION OF COMPONENTS
AIR/OIL COALESCER
The coalescer is self-contained within a spin-on housing. When air is demanded at the service line,
it passes through the coalescer which efficiently provides the final stage of oil separation.
OIL RETURN LINE
The oil that is removed by the coalescer accumulates and is returned through an internal oil return
line leading to the compressor.
MINIMUM PRESSURE VALVE
The minimum pressure valve is located at the outlet of the coalescer head and serves to maintain a
minimum discharge pressure of 75 PSIG in operation, which is required to assure adequate
compressor lubrication pressure.
OIL FILTER
The compressor oil filter is a removable and cleanable screen built into the side of the compressor
housing. Screen replacement may be necessary after several cleanings.
COMPRESSOR OIL COOLING SYSTEM
The compressor cooling system consists of a combination hydraulic cooler and compressor cooler
mounted on the common frame. Compressor oil temperature is controlled by a thermal valve
located down stream of the oil filter. The thermal valve maintains the compressor oil temperature
at 185ºF. Cool air is drawn through the vented end panel and across the combo cooler. The air is
heated by the coolers and the hot air exits out the back vented panel . Allow for adequate
clearance (12”) for the air to exit. Also, the package location should not be subjected to above
ambient air temperatures.
HYDRAULIC COOLING SYSTEM
The machine is equipped with an integrated hydraulic cooler that is effective up to 90°F ambient
temperature. If running at a higher ambient temperature, an additional hydraulic cooler is required.
The system cooler is not designed for any additional heat load created from auxiliary components.
For hydraulic cooler recommendations, please contact your local Auto Crane distributor.
14
DESCRIPTION OF COMPONENTS
INSTRUMENTATION
The AUTO CRANE hydraulic drive compressor unit incorporates a gauge panel that monitorstemperature, pressure and hours of operation.
HOURMETER
The hourmeter records the total number of operating hours. It serves as a guide in following therecommended inspection and maintenance schedule. The hourmeter will only run when there is pressurein the system.
COMPRESSOR DISCHARGE AIR/OIL TEMPERATURE SWITCHGAUGE
This switchgauge indicates compressor air discharge temperature. The switchgauge ensures safetyshutdown in case of excessive operating temperatures, preventing compressor damage, by stoppinghydraulic flow to the compressor motor.
ELECTRICAL AND SAFETY SYSTEM
The AUTO CRANE compressor’s standard electrical system consists of:-Gauge panel with a temperature switchgauge, hourmeter and discharge pressure switchgauge.-Compressor and hydraulic oil cooler fan assembly and relay.-Compressor after cooler/oil cooler fan assembly and relay.-3-way pressure switch and relay to control hourmeter and blowdown.-12VDC N.O. hydraulic solenoid and relay.-Switch relay for customer equipment interface during compressor operation.-Differential pressure switch for air filter maintenance.-Optical oil level switch and relay.
15
DESCRIPTION OF COMPONENTS
CONTROL SYSTEM
The prime component of the compressor control system is the compressor inlet valve. The controlsystem is designed to match air supply to air demand and to prevent excessive discharge pressurewhen compressor is at idle. Control of air delivery is accomplished by the inlet valve regulationand modulation as directed by the discharge pressure regulator.
NORMALLY OPEN REGULATOR SOLENOID
A closed Furnas air pressure switch will energize the normally open regulator solenoid, thus closingit. When the normally open regulator solenoid is closed, air pressure will rise. When it is open airpressure falls only in the compressor sump.
NOTE: Most air tools operating pressure range is between 90 and 125 psi. Operatingabove the tools recommended pressures will decrease the life of the tool. Higheroperating pressure can also over torque nuts and bolts fatiguing the fastener and matingparts. Strictly adhere to tool operating pressures and torque standards set forth by thetool manufacturer and the specifications of the equipment that work is being performedon.
FURNAS SWITCH DESCRIPTION
The Furnas switch is a N.C. electrical switch set to open at 150 PSI and set to close at 115 PSI.
The Furnas switch controls the N.O. regulator solenoid. If service air pressure is under 150 PSI,
the Furnas switch will not trip keeping the N.O. inlet valve open and the compressor making air. If
the service valve is closed or the tool using the air is off, service line pressure will rise over 150
PSI. This will trip the Furnas switch to open. The regulator solenoid will open and send air
pressure to the inlet valve to close. With the inlet valve closed, the compressor will stop making
air. If the tool is turned on or the service valve is opened, the service line pressure will drop.
When the pressure falls to 115 PSI the Furnas switch will close energizing the N.O. regulator
solenoid closing off the air supply to the inlet valve. This will allow the inlet valve to open, and the
compressor will start making air to meet the demand.
INLET VALVE
The compressor inlet valve is a piston operated disc valve that regulates the inlet opening to controlcapacity and serves as a check valve at shutdown.
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INSPECTION, LUBRICATION, AND MAINTENANCE
This section contains instructions for performing the inspection, lubrication, and maintenance
procedures required to maintain the compressor in proper operating condition. The importance of
performing the maintenance described herein cannot be over emphasized.
The periodic maintenance procedures to be performed on the equipment covered by this manual
are listed below. It should be understood that the intervals between inspections specified are
maximum interval. More frequent inspections should be made if the unit is operating in a dusty
environment, in high ambient temperature, or in other unusual conditions. A planned program of
periodic inspection and maintenance will help avoid premature failure and costly repairs. Daily
visual inspections should become a routine.
The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressor
package. The items are listed according to their frequency of maintenance, followed by those
items which need only “As Required” maintenance.
The maintenance time intervals are expressed in hours. The hourmeter shows the
total number of hours your compressor has run. Use the hourmeter readings for determining your
maintenance schedules. Perform the maintenance at multiple intervals of the hours shown. For
example, when the hourmeter shows “100” on the dial, all items listed under “EVERY 10 HOURS”
should be serviced for the tenth time, and all items under “EVERY 50 HOURS” should be
serviced for the second time, and so on.
DANGER
COMPRESSOR MUST BE SHUT DOWN AND COMPLETELY RELIEVED OFPRESSURE PRIOR TO CHECKING FLUID LEVELS. OPEN SERVICE VALVE TOENSURE RELIEF OF SYSTEM AIR PRESSURE. FAILURE TO COMPLY WITH THISWARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM.
17
LUBRICATION AND MAINTENANCE CHART
NOTE: Compressor oil and filter is to be changed after the first 50 hours of operation. After this,
normal intervals are to be followed.
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18
LUBRICANT RECOMMENDATIONS
WARNING
The following are general characteristics for a rotary screw lubricant. Due to the impossibility of
establishing limits on all physical and chemical properties of lubricants which can affect their
performance in the compressor over a broad range of environmental influences, the responsibility
for recommending and consistently furnishing a suitable heavy duty lubricant must rest with the
individual supplier if they choose not to use the recommended AUTO CRANE rotary screw
lubricant. The lubricant supplier’s recommendation must, therefore, be based upon not only the
following general characteristics, but also upon his own knowledge of the suitability of the
recommended lubricant in helical screw type air compressors operating in the particular
environment involved.
CAUTION
IT IS IMPORTANT THAT THE COMPRESSOR OIL BE OF A RECOMMENDEDTYPE AND THAT THIS OIL AS WELL AS THE AIR FILTER, OIL FILTER, ANDCOALESCER ELEMENTS BE INSPECTED AND REPLACED AS STATED IN THISMANUAL.
THE COMBINATION OF A COALESCER ELEMENT LOADED WITH DIRT ANDOXIDIZED OIL PRODUCTS TOGETHER WITH INCREASED AIR VELOCITY AS ARESULT OF THIS CLOGGED CONDITION MAY PRODUCE A CRITICAL POINTWHILE THE MACHINE IS IN OPERATION WHERE IGNITION CAN TAKE PLACEAND COULD CAUSE A FIRE IN THE OIL SUMP.
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TOPROPERTY AND SERIOUS BODILY HARM.
MIXING DIFFERENT TYPES OR BRANDS OF LUBRICANTS IS NOTRECOMMENDED DUE TO THE POSSIBILITY OF A DILUTION OF THEADDITIVES OR A REACTION BETWEEN ADDITIVES OF DIFFERENT TYPES.
19
LUBRICANT RECOMMENDATIONS
LUBRICANT CHARACTERISTICS
1. Flash point 400°F minimum.2. Pour point -40°F.3. Contains rust and corrosion inhibitors.4. Contains foam suppressors.5. Contains oxidation stabilizer.
NOTE
NOTE
DUE TO ENVIRONMENTAL FACTORS THE USEFUL LIFE OF ALL “EXTENDEDLIFE” LUBRICANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANTSUPPLIER. AUTO CRANE ENCOURAGES THE USER TO CLOSELY MONITORTHE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OIL ANALYSISPROGRAM WITH THE SUPPLIER.
NO LUBRICANT, HOWEVER GOOD AND/OR EXPENSIVE, CAN REPLACEPROPER MAINTENANCE AND ATTENTION. SELECT AND USE IT WISELY.
20
MAINTENANCE
If some of the maintenance intervals in the schedule outlined in this manual seem to be rather short,
it should be considered that one hour’s operation of a compressor is equal to about 40 road miles
on an engine. Thus, eight hours operation is equal to 320 road miles, 250 hours is equal to 10,000
road miles, etc.
COMPRESSOR OIL SUMP FILL, LEVEL, AND DRAIN
Before adding or changing compressor oil make sure that the compressor is completely relieved of
pressure. Oil is added at the fill cap on the side of the compressor body. A drain valve/hose
assembly is provided at the bottom of the compressor body. The proper oil level is between the
top and the midpoint of the oil sightglass, when the unit is shut down and has had time to settle.
The truck must be level when checking the oil. DO NOT OVERFILL. The oil sump capacity is
given in “Compressor Specifications”.
DO NOT ATTEMPT TO DRAIN CONDENSATE, REMOVE THE OIL LEVEL FILLPLUG, OR BREAK ANY CONNECTION IN THE AIR OR OIL SYSTEM WITHOUTSHUTTING OFF COMPRESSOR AND MANUALLY RELIEVING PRESSURE FROMTHE SUMP. FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGETO PROPERTY AND SERIOUS BODILY HARM.
IF COMPRESSOR IS NOT OPERATED AT FULL SYSTEM TEMPERATURE (170°F)WEEKLY, COMPRESSOR OIL SHOULD BE CHANGED MONTHLY.
AIR INTAKE FILTER
The air intake filter is a heavy-duty dry type high efficiency filter designed to protect the
compressor from dust and foreign objects. Optional two-stage available.
Optional filter is equipped with an evacuator cup for continuous dust ejection while operating and
when stopped.
Frequency of maintenance of the filter depends on dust conditions at the operating site. The filter
element must be serviced when clogged (maximum pressure drop for proper operation is 15” of
water). The filter is equipped with a pressure drop indicator, and the element should be changed
based on its reading first and then by the maintenance intervals outlined.
WARNING
DANGER
21
MAINTENANCE
AIR/OIL COALESCER
The air/oil coalescer employs an element permanently housed within a spin-on canister. This is a
single piece unit that requires replacement when it fails to remove the oil from the discharge air, or
pressure drop across it exceeds 15 PSI. Dirty oil clogs the element and increases the pressure
drop across it.
To replace element proceed as follows:
1. Shutdown compressor and wait for complete blow down (zero pressure).
2. Turn element counterclockwise for removal (viewing element from bottom).
3. Apply a film of fluid directly to seal on the new element.
4. Rotate element clockwise by hand until element contacts seal (viewing element from
bottom).
5. Rotate element approximately one more turn clockwise with band wrench near the top
of element.
6. Run system and check for leaks.
WARNING
COALESCER OIL RETURN
This originates at the bottom of the air/oil coalescer and flows through a special recovery pipe and
venturi nozzle. If the coalescer starts to fill with oil there is a good chance the venturi or pipe has
been plugged. Consult factory for cleaning instructions.
DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE AUTO CRANEREPLACEMENT ELEMENT. THIS ELEMENT IS RATED AT 200 PSI WORKINGPRESSURE. USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULDIMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR,POSSIBLY VOIDING THE WARRANTY AND/OR RESULTING IN DAMAGE TOPROPERTY AND SERIOUS BODILY HARM.
22
MAINTENANCE
OIL FILTER
The compressor oil filter is a throwaway type cartridge. It is designed with a built-in bypass so that
if there is a large restriction, due to cold oil or clogged element, the compressor will still be
lubricated.
To replace filter proceed as follows:
1. Make sure system pressure is relieved.
2. Unscrew with 14mm allen wrench.
3. Remove oil filter from housing.
4. Replace the oil filter screen element.
5. Reinsert oil filter screen into housing and tighten with 14mm allen wrench.
6. Add oil (total system takes one gallon), re-tighten filler cap.
7. Check for leaks in operation.
WARNING
HYDRAULIC OIL COOLER AND COMPRESSOR OIL COOLER COMBINATION
The interior of the oil cooler should be cleaned when the pressure drop across it at full flow
exceeds 25 PSI. The following procedure has been recommended by the vendor who supplies the
cooler:
1. Remove cooler.
2. Circulate a suitable solvent to dissolve and remove varnish and sludge.
3. Flush generously with compressor lubricant (compressor oil cooler section only, use
hydraulic oil to flush the hydraulic cooler portion on the combo cooler).
4. Once the coolers are reinstalled, fill the compressor and hydraulic systems with the
proper fluids to their appropriate levels.
DO NOT SUBSTITUTE ELEMENT. USE ONLY A GENUINE AUTO CRANEREPLACEMENT ELEMENT. USE OF ANY OTHER ELEMENT MAY BEHAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITYOF THE COMPRESSOR, POSSIBLY VOIDING THE WARRANTY AND/ORRESULTING IN DAMAGE TO PROPERTY AND SERIOUS BODILY HARM.
23
MAINTENANCE
SHAFT SEAL
SHAFT SEAL INSTALLATION INSTRUCTIONS:
1. Remove hydraulic motor, drive coupling and adapter housing from face of compressor.
2. Remove coupling hub from compressor shaft.
3. Remove 4 screws from shaft seal cover and press seal out.
4. Pull seal wear sleeve off shaft with puller.
5. Clean shaft surface removing all burrs from shaft where the wear sleeve gets installed.
6. Press new wear sleeve on to shaft. Oil heating new wear sleeve to 212°F approximately
aids in the installation of this ring.
7. Press new seal into housing with seal assembly tool, until contact with snapring.
8. Temporarily install new seal installation cone over shaft to protect seal during reinstallation.
9. Reinstall cover.
10. Reinstall coupling hub to compressor shaft.
11. Reinstall adapter housing, drive coupling, and hydraulic motor to face of compressor.
24
TROUBLESHOOTING
This section contains instructions for troubleshooting the equipment following a malfunction.
The troubleshooting procedures to be performed on the equipment are listed below. Eachsymptom of trouble for a component or system is followed by a list of probable causes of thetrouble and suggested procedures to be followed to identify the cause.
In general, the procedures listed should be performed in the order in which they are listed, althoughthe order may be varied if the need is indicated by conditions under which the trouble occurred. Inany event, the procedures which can be performed in the least amount of time and with the leastamount of removal or disassembly of parts, should be performed first.
UNPLANNED SHUTDOWN
When the operation of the machine has been interrupted by an unexplained shutdown, check thefollowing:
1. Check the fuel level and truck dash gauges and indications for possible engineproblems.
2. Check the compressor discharge temperature/switchgauge. If the latching relay circuitis tripped the 12VDC solenoid will lose power and divert hydraulic oil back to thereservoir. The compressor blowdown pressure switch and the temperature switchgaugewill not allow power to the hydraulic solenoid until the air has blown down and thetemperature has dropped into its normal operating range and the push button has beenreset. Take compressor in for service once a high temperature shutdown has occurred.Failure to do so will void your warranty.
3. Check that the compressor oil is at proper level.4. Check oil cooler for dirt, slush, ice on the fins, or any other obstructions to the cooling
air flow.5. Make a thorough external check for any cause of shutdown such as broken hose,
broken oil lines, loose or broken wire, etc.
25
TROUBLESHOOTING
IMPROPER DISCHARGE PRESSURE
1. If discharge pressure is too low, check the following:
A. Too much air demand. (Air tools require more air than what the compressor can
produce, air tools are free wheeling without resistance.)
B. Service valve wide open to atmosphere.
C. Leaks in service line.
D. Restricted compressor inlet air filter.
E. Faulty control system operation (i.e.N.0. regulated air solenoid is allowing air through
all the time.)
F. Furnas Switch is not closing at 115 psi.
G. Low compressor oil level.
2. If discharge pressure is too high, safety valve blows, or system shuts down on high pressure,
check the following:
A. Faulty discharge pressure switchgauge.
B. Coalescer plugged up.
C. Faulty safety valve.
D. N.O. regulated air solenoid is not opening.
E. Furnas switch is not opening at 150 psi.
3. Sump relief valve activates:
A. Inlet valve leaking or open.
B. Faulty relief valve.
C. Faulty Furnas switch, or N.O. regulated air solenoid, or pressure switchgauge.
SUMP PRESSURE DOES NOT BLOW DOWN
If after the compressor is shutdown, pressure does not automatically blow down, check for:
1. Normally open regulated air solenoid may be stuck closed.
2. Blockage in air line from downstream of the coalescer to the inlet valve.
3. Inlet valve orifice is clogged.
OIL CONSUMPTION
Abnormal oil consumption or oil in service line, check for the following:
1. Over filling of oil sump.
2. Leaking oil lines or oil cooler.
3. Plugged oil return line: check nozzle beneath the sightglass.
4. Defective coalescer element.
5. Compressor shaft seal leakage.
26
TROUBLESHOOTING
COALESCER PLUGGING
If the coalescer element has to be replaced frequently because it is plugging up, it is an indication
that foreign material may be entering the compressor inlet or the compressor oil is breaking down.
Compressor oil can break down prematurely for a number or reasons.
(1) Extreme operating temperature, (2) negligence in draining condensate from oil sump, (3) using
the improper type of oil, (4) dirty oil, (5) oil return nozzle plugged.
The complete air inlet system should be checked for leaks.
HIGH COMPRESSOR DISCHARGE TEMPERATURE
1. Check compressor oil level. Add oil if required (see Section for oil specifications).
2. Check thermal valve operation.
3. Clean outside of oil cooler.
4. Clean oil system (cooler) internally.
5. Check fan relay harness.
27
COMPRESSOR OPERATION
Before starting the compressor, read this section thoroughly. Familiarize yourself with the controls and
indicators, their purpose, location, and use.
ROLORTNOCROTACIDNI
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28
COMPRESSOR OPERATION
OPERATING CONDITIONS
The following conditions should exist for maximum performance of the compressor. The truck
should be as close to level as possible when operating. The compressor will operate on a 15
degree sideward and lengthwise tilt without any adverse problems. Operation in ambient tempera-
tures above 100°F (38°C) may experience high temperature shutdown.
NOTE
NOTE
IF THE COMPRESSOR IS BEING USED TO POWER SANDBLASTING EQUIP-MENT, OR AN AIR STORAGE TANK, USE A CHECK VALVE DIRECTLY AFTERTHE MINIMUM PRESSURE VALVE TO PREVENT BACKFLOW INTO THE SUMP.THIS CHECK VALVE SHOULD HAVE A MAXIMUM PRESSURE DROP RATINGOF 2 PSIG (13.78kPa) OPERATING AND A CAPACITY RATING EQUAL TO THECOMPRESSOR.
A COMPRESSOR SERVICE VALVE SHOULD BE LOCATED TO THE HOSE REELINLET OR THE CUSTOMERS AIR CONNECTION PORT WHEN A HOSE REEL ISNOT USED. TYPICAL PLUMBING FROM THE MACHINE’S AIR OUTLET PORTOCCURS IN THE FOLLOWING ORDER:
1. MINIMUM PRESSURE ORIFICE.2. CHECK VALVE.3. AIR TANK (WHEN USED).4. OSHA VALVE.5. SERVICE VALVE6. MOISTURE TRAP/GAUGE/OILER COMBINATION (WHEN USED).7. HOSE REEL (WHEN USED).
29
PARTS AND
ILLUSTRATION
SECTION
30
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
AA
BB
CC
DD
Par
ts L
ist
DE
SC
RIP
TIO
NP
AR
T N
UM
BE
RQ
TY
ITE
M
CO
MP
R M
TG
SY
S, R
S60
AC
45/
60/1
50 S
CI8
G20
0359
11
ELE
C S
YS
, RS
60A
C 4
5-60
-150
SC
I8G
2003
581
2O
IL-A
IR-H
YD
CLN
G S
YS
, RS
60A
C S
CI8
G20
0360
13
CA
NO
PY
SY
S, R
S60
AC
45-
60-1
50 S
CI8
G20
0357
14
OP
T, R
S60
SH
IPP
ING
MA
TE
RIA
LS61
284
1N
SK
IT, H
OS
E IN
FIN
ITY
8009
91
NS
SH
EE
T
2006
7-00
11
1 O
F
RE
V14
RS
60A
C 4
5-60
SC
IG
AU
TO
CR
AN
EP
.O. B
OX
580
697
TU
LSA
, OK
741
58-0
697
N/A
PA
TH
MA
TE
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L
G:\I
nven
tor
File
s\20
k\20
067-
001.
dwg
12/3
/200
7
12/3
/200
7D
CL
DR
AW
N
ND
DC
HE
CK
ED
1=4
D
DE
SC
RIP
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N
DW
G N
OS
CA
LES
IZE
UN
MA
CH
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D S
UR
FA
CE
S
FR
AC
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NA
L `
1/1
6
DE
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AN
GU
LAR
` 1
°
DO
NO
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LE
TOL
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AN
CE
SU
NL
ES
S N
OT
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MA
CH
INE
D S
UR
FA
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S
NO
MIN
AL
DIM
.
0.00
0 T
O 1
.000
.
010
1.00
1 T
O 5
.000
.
015
5.00
1 T
O 1
0.00
0 `
.020
10.0
01 &
OV
ER
`.0
25
TH
IS D
RA
WIN
G A
ND
ALL
IN
FO
RM
AT
ION
TH
ER
EIN
IS
TH
E P
RO
PE
RT
Y O
F A
UT
O
CR
AN
E, I
S C
ON
FID
EN
TIA
L A
ND
MU
ST
NO
T B
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AD
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PU
BLI
C O
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. IT
IS
LO
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SU
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TO
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IS N
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TO
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D
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R IN
DIR
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WA
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TA
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F
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TO
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AN
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PR
OP
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TA
RY
IN
FO
RM
AT
ION
34 3
/4 in
[882
.7 m
m]
32 1
/4 in
[819
.2 m
m]
17 3
/4 in
[450
.9 m
m]
6 3/
8 in
[163
.2 m
m]
5 in
[127
.0 m
m]
19 in
[481
.4 m
m]
20 1
/4 in
[514
.4 m
m]
DIM
EN
SIO
NS
OF
MO
UN
TIN
G H
OLE
S
14U
PD
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20
0359
TO
RE
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MC
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003
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8.
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20
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6.
11/8
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20
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20
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61
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TO
RE
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MC
M
RE
VIS
ION
HIS
TO
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RE
VD
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CR
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ION
DA
TE
EN
G
31
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
AA
BB
CC
DD
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DE
SC
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NP
AR
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RQ
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M
BA
SE
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FIN
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3023
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29
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DIC
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35
36
RECOMMENDED SPARE PARTS
REBMUNTRAP NOITPIRCSED
100-005557 8ICSRETLIFLIO,TNEMELE
200-005557 8/7ICSRETLIFRIA,TNEMELE
300-005557 8ICSNO-NIPS,RECSELAOC
500-005557 G8ICSRIAPERLAESTFAHS,TIK
700-005557 GNILPUOC,REDIPS
800-005557 RIAPERLAESTFAHSROTOMDYH,TIK
900-005557 8ICSLAMREHT,EVLAV
010-005557 OR4/3"A"EASRIC85.1,ROTOM
110-005557 82RYWYK7X8XMM52GNILPUOC,BUH
210-005557 61/3WDNUOR4/3GNILPUOC,BUH
310-005557 8ICSTELNI,EVLAV
640-005557 RETLIFRIA8ICS,TEKSAG
37
DATE:__________
1. Information given by:______________________________________________
2. Information received by:____________________________________________
3. Has anyone helped you: Yes______ No______
4. Distributor:_____________________________________________________
5. End-User:________________________________________________________
6. Phone Number:___________________________________________________
7. Make and Model for PTO:__________________________________________
8. AUTO CRANE Serial #:_______________________________________
9. Make and Model of Engine:_________________________________________
10. Engine:________________________________________________________
11. Transmission:___________________________________________________
12. Nature of Problem:________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________
13. Engine RPM:_____________________________________________________
14. Compressor RPM:________________________________________________
15. Action Taken:_____________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________
Additional Comments:___________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
______________________________________________________________________________________________________________________________________________________________________________________________________________________________
SERVICE QUESTIONNAIRE
38
+12V POWER (16 GA. YELLOW)
SPEED CONTROL OUT (16 GA. ORANGE)
GROUND (14 GA. BLACK)
+12V POWER (14GA. RED)
17.7511.42
6.42 22.6632.25
9.59
7/16" DIA.
6-PLACES
TRUCK MOUNTING SURFACE
Instructional Procedures for Installation of AUTO CRANE RS60AC Geared Rotary Screw Air
Compressor
This air compressor should be installed only by those who have been trained and delegated todo so and who have read and understand both the operators’ manual and the installation manual.Failure to follow the instructions, procedures, and safety precautions in this manual may result inaccidents and injuries.
Install, use, and operate this air compressor only in full compliance with all pertinent O.S.H.A.requirements and all pertinent Federal, State, and Local codes or requirements and with AUTOCRANE instructions.
Do not modify this compressor except with written factory approval.
WARNING
1. MOUNTING COMPRESSORWhen mounting the compressor care should be taken to ensure that its location does not im-pede the operation of other components on the vehicle. For example, if your vehicle is equippedwith a crane, you must make sure the compressor will not interfere with the swing of the crane.In addition, the compressor should be installed in an area that permits cool ambient air to enterthe air filter and the hot air from the cooler to exhaust without recirculating into the air filter. Onelast consideration in the mounting should be the routing of hoses and electrical wires. The framemounting holes are shown below and the unit should be secured to the vehicle with 3/8 inchgrade 8 bolts, washers should be used on the mounting surface. Hardware supplied with unit,may not work in all applications.
TO AVOID ANY POTENTIAL OVERHEATING ISSUES, ENSURE CLEARANCE OFATLEAST 12” AROUND ALL CANOPY OPENINGS.
39
INSTRUCTIONAL PROCEDURES
2. INSTALLING THE WIRING & CONNECTING THE HYDRAULIC HOSES
This unit is shipped from the factory with all necessary internal wiring installed. The only remain-ing wiring necessary is the wiring needed to interface your vehicle/power source with the AUTOCRANE compressor. (Please refer to drawing 307193 on page 35) The unit is shipped with 4loose wires, they need to be connected as follows:
1. Connect red wire to switched 12 vdc power. (or 24 VDC if you have this option)2. The yellow wire should be spliced into the 12 vdc switched feed for the on/off switch
per the end-users location.(or 24 VDC if you have this option)3. Connect black wire to ground.4. The orange wire is used to activate an electronic speed control circuit if required.
Please contact the factory with engine specific information for further assistance.
CONNECTING THE HOSES
The hydraulic hoses to the compressor should be connected directly to the hydraulic controlblock. The pressure “P” input line should be made from a good quality high pressure (min. 3000PSI) hydraulic hose 3/4” i.d. The return line to tank “T” can be made from a medium pressure(min. 1000 PSI) hydraulic hose 1” i.d. Care should be taken to see that the hoses are not in-stalled with kinks or bends that inhibit flow of the hydraulic oil. Lack of flow could result in dam-age to the motor and compressor. Lastly check to make sure hoses are not in contact withsharp objects or edges that may fray, chafe or cut them over time. Secure all hoses with tiedown straps or clamps.
HYDRAULIC RESERVIOR
The RS60AC is designed to operate with a 25 gallon hydraulic reservior minimum. If additionalhydraulic components are utilized, the reservior should be sized for 25 gallons plus the recom-mended capacity by the other component manufacturers.
40
INSTRUCTIONAL PROCEDURES3. PRE-START-UP INSPECTION CHECKS
This inspection should be done prior to removing truck from bay. Final testing of the system,including checking for leaks, is to be done outside.
ALL TRUCKS SHOULD BE ROAD TESTED PRIOR TO STARTING INSTALLATION TO ISOLATE ANY
PREVIOUS TRUCK PROBLEMS.I. Check sales order to verify that all compressor related items originally ordered have
been installed or are ready to ship with the truck. This would include any special filters,oils, hoses, options, etc.
II. Vacuum all areas that have metal or plastic shavings. Wipe all fingerprints off unit andvehicle.
III. Apply decals to proper location. Make sure that the area is cleaned prior to applyingdecals. All decals should have a professional appearance upon application.
IV. Check all assemblies, clamps, fittings, drivelines, angles, nuts, and bolts to ensure theyare properly tied and secured to the vehicle. This is a very critical area of inspection.The vehicle should not be moved until this inspection has been completed.
V. Record all serial numbers for this installation.A. Vehicle V.I.N.B. Hydraulic Pump DataC. Air-End Serial NumberD. AUTO CRANE Serial NumberE. Receiver Tank Serial NumberF. Note any special applications relating to specific installations.
VI. Check all fluid levels (position the unit on a level surface so that proper amount of fluidscan be added).
A. Fuel to provide for three hours of operation.B. Transmission fluid and PTO box.C. Compressor. Check the compressor oil sump level (see lubricant section of the operator and parts section for type of lubricant to use). 1. Add oil if needed. 2. Additional oil may need to be added after test. 3. Top off oil level to half the sightglass when finished with the test.
D. Any other applicable fluids.
4. INITIAL START-UP AND TEST
A. Start power source and allow for warm-up.B. Read the operation section in the operator and parts manual carefully before proceeding onto
the initial start-up.
41
INSTRUCTIONAL PROCEDURESC. Engage hydraulic system. A direction of rotation arrow is attached to the compressor pack-
age above the hydraulic coupling. The coupling/hub must be rotating in the direction thearrow is pointing. If for any reason this arrow has been removed the correct compressorrotation is clockwise when looking directly at the compressor shaft. Check the direction ofrotation by quickly engaging and then disengaging the compressor.
CAUTIONDO NOT RUN THE COMPRESSOR IN A REVERSE ROTATION FOR PERIODS LONGER
THAN 5 SECONDS. CONTINUED OPERATION IN THIS MANNER WILL RESULT INEXTENSIVE COMPRESSOR UNIT DAMAGE.
The safety shutdown switch should be wired in series with the solenoid that opens the flow ofthe hydraulic oil to the compressor drive motor. In cases of high temperature and/or pressure,the closing of the valve will stop the compressor operation.
Safety circuit testing for RS60AC
Safety circuit testing can be done in the following manner. Start the truck. Engage the com-pressor. Take a screwdriver and touch the 1/16” allen head screw on the face of the tempera-ture gauge and simultaneously touch the outside ring on the face of the gauge. This should shutoff the power to the solenoid of the hydraulics. Push the button in on the shutdown switch toreset. Repeat the test with the pressure gauge if solenoid does not stop flow to compressor,check wiring.
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The RS60AC is designed to provide continuous CFM output and constant pressure withoutthe use of an air reservoir. Air reservoirs are not typically installed on vehicle mountedrotary screw compressors and Auto Crane does not recommend an air reservoir be in-cluded as standard equipment for use with the RS60AC compressors
The above not withstanding, Auto Crane understands that some of our customers want anair reservoir installed on their vehicle in order to facilitate air usage when the vehicle’scompressor is not running. Auto Crane also understands that unless properly installed, theair reservoir, plumbing to the reservoir, and subsequent connections and plumbing to thehose reel, along with the hose reel itself, may restrict the flow of usable air delivered to thetool.
The following is a recommendation for using an air reservoir in conjunction with theRS60AC product.
I. Air Reservoira. The recommended minimum size of the air reservoir should be 6930 cubic
inches (30 gallons). The actual size of the air reservoir can be larger orsmaller depending on the duration and demand of air required during theperiods of time that the vehicle is not running.
II. Specifications of the Air Reservoira. Must meet DOT requirements for air reservoir constructionb. Must include a safety relief valve with a maximum relief valve setting of
175psi.c. Must include drain port located at the lowest point to permit the drainage of
moisture that normally occurs during the compression of air.d. The drain port should be fitted with a pet cock or other easily operable drain
valve to promote regular maintenance of the air system.III. Connections and Plumbing
a. RS60AC compressor discharge line should be .75" ID and rated for 250F,300psi minimum.
b. Fittings should be .75" ID to minimize air system restrictions.c. Hose reel should be .75" ID to minimize air system restrictions.d. Line droops or condensate traps plumbed into the system should be
avoided.IV. Air System PlumbingThe air reservoir plumbing should be designed to maximize the capabilities of the
RS60AC product and air delivery from the hose reel for the operation high volume airconsuming tools. The following schematic is recommended.
RS60AC WITH AIR RESERVOIR APPLICATIONRECOMMENDATION
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RS60 Compressor
Air Reservoir
Hose Reel
Vehicle Accessories
(if any)
Drain
Check Valve
Filter/Reg./Lubr.
RS60AC WITH AIR RESERVOIR APPLICATIONRECOMMENDATION
RS60AC with Air Reservoir Schematic Recommendation