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MODEL SHD-66DD OWNER’S MANUAL Safety • Operation • Installation • Maintenance Subject to Change without Notification. © 2014 American Eagle. American Eagle, Inc. 740 N. State Street PO Box 169 Garner, IA 50438 800-392-3015 Fax: 641-923-9099 www.americaneagleacc.com Last Revision: 05/28/14 ii AE Compressor Manual Revisions AE SHD66DD Owner’s Manual Date of Revision Section Revised Description of Revision August 2013 All Sections Updated to new style compressor May 2014 Assembly Drawings Updated to new shroud design Introduction 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 1 [email protected] [email protected] [email protected] 2 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..............................................16 Typical Hydraulic Circuit for Single Stage Pump with Multiple Components..............................................17 Typical Hydraulic Circuit for Compressor ...................................18 with Auxiliary Cooler .................................................................18 Chapter 6: Assembly Drawings ...................................................19 Compressor Assembly Drawing ..................................................19 Compressor Assembly Bill ..........................................................20 Shroud Assembly ........................................................................21 Crankcase, Flywheel, Cylinders, & Centrifugal Unloader ...........22 Crankshaft, Rod, & Piston...........................................................23 Valve, Manifold, & Filter...............................................................24 Tubing Assembly .........................................................................25 Chapter 7: Replacement Parts .....................................................27 Chapter 8: Troubleshooting ..........................................................2 3 4 AE SHD66DD Owner’s Manual Chapter 1: Safety Safety 5 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. 6 AE SHD66DD Owner’s Manual Chapter 2: Specifications Specifications Drive System Description • 18 GPM Hydraulic System • 2200 PSI System Pressure • All Steel Plumbing W/ JIC Fittings • 165 Sq. In., 300 BTU Cooler • 2700 PSI Pressure Relief Setting • 12 VDC Solenoid Control Valve • 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 • Precision Balanced Flywheel • Pressure Relief Valves in interstage and discharge • Gasket-free Integrated Cylinder/Head • Heavy Ductile Iron Crankshaft • Large Diameter Finned Inner Cooling Tubing • Positive Acting Centrifugal Head Unloaders • • • • • • • • Splash Lubricated System • 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 7 8 AE SHD66DD Owner’s Manual Chapter 3: Operation Operation 9 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. Inspect unit for any visible signs of damage. Before Start-Up 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. 10 AE SHD66DD Owner’s Manual Head Unloading System Intake Valve Hold-Open Mechanism C A (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 (D) and back off several turns. Do not turn differential adjuster (C). 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 (A) clockwise to increase pressure or counterclockwise to decrease pressure. 3.) After pressure is set, tighten locknut (D). Be careful not to move the threaded cap (A). D B Differential Pressure Adjustment: Proceed with the following while the compressor is running. 1.) Loosen locknut (B) 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 (C) clockwise to increase differential pressure or counterclockwise to decrease differential pressure. 3.) After pressure is set, tighten locknut (B). Be careful not to move nut (C) Chapter 4: Maintenance Maintenance 11 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. Maintenance operation Drain air tanks Service Intervals Daily Weekly Monthly Hourly 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 air filters 3 Replace hydraulic filter Tighten all fittings and fasteners Check all electrical connections Inspect and clean air check valve CHANGE CRANKCASE OIL (see footnote below) 6 3 3 250 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. 12 AE SHD66DD Owner’s Manual Chapter 5: Installation Installation 13 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. 14 Component Installation Continued... AE SHD66DD Owner’s Manual Pilot Air From Air Tank Compressed Air Supply Case Drain Connect Directly Tank Hydraulic Return To Tank Hydraulic Supply From Pump Electrical Connection Crank Case Drain Component Installation Continued... Installation Stellar Supplied Reservoir Connect 1-1/4” Suction Hose to 1-1/4” Barb Fitting. Motor case drain routed to hydraulic reservoir 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 are bulkhead fittings to which hydraulic lines are attached. To the appropriate fitting (see drawing detailing front of compressor), 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 hydraulic return fitting and is routed to the oil reservoir through a filter. The case drain line from the hydraulic motor is also routed to the oil reservoir (DO NOT INSTALL A FILTER ON THE CASE DRAIN LINE). 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 A See Detail B 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. 15 16 AE SHD66DD Owner’s Manual 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 Installation Typical Hydraulic Circuit for Compressor with Auxiliary Cooler HYDRAULIC RESERVOIR FILTER FILTER SCREEN AUXILIARY COOLER SUCTION PORT SINGLE HYDRAULIC PUMP COMPRESSOR RETURN PRESSURE 17 18 AE SHD66DD Owner’s Manual Chapter 6: Assembly Drawings Assembly Drawings Shroud Assembly 11 6 5 8 3 17 12 1 14 1 4 6 5 15 16 15 2 13 15 14 6 7 14 14 15 5 6 ITEM 1 PART 65875 2 69517 3 4 5 6 65877 19589 19592 C6021 7 70473 8 70474 9 70379 10 70379 11 69101 12 73654 13 73653 14 15 16 17 D0917 0333 70475 73724 D E SCRI PTION QTY. PANEL SIDE SHD66 SHROUD BH PC WHITE 1 PANEL FRONT SHD66 SHROUD BULKHEAD 1 PC WHITE PANEL REAR SHD66 SHROUD PC WHITE 1 NUT SERT 0.25-20X0.38 OD 16 WASHER 0.25 FLAT NYLON 22 CAP SCR 0.25-20X0.75 BTNHD SS 26 PANEL SIDE RH SHD66 SHROUD BH V3 PC 1 WHITE PANEL LID CPRSR SHD66 SHROUD PC 1 WHITE HINGE ZINC BLK FLUSH SURFACE MNT DC1 50-P8 HINGE ZINC BLK FLUSH SURFACE MNT DC1 50-P8 LATCH SWING LEVER FLUSH TRIGGER 0.912 1.81 BRKT LID GASPROP CPRSR SHROUD V2 PC 2 WHITE BRKT LOWER GASPROP CPRSR SHROUD 2 V2 PC WHITE WASHER 0.25 FLAT SS 18 NUT 0.25-20 HHGR5 NYLOC 18 GAS SPRING 7.50-12.00 60# FORCE 2 WEATHERSTRIP RIBBED 0.38X0.13X117.00 1 10 19 58 13 12 53 27 41 56 35 4 2 46 17 43 4 9 29 8 34 23 64 37 7 11 29 31 57 21 50 16 55 30 44 25 33 27 26 58 72 18 48 47 42 74 22 15 6 45 19 14 71 75 29 63 5 70 5 3 66 22 54 15 60 49 68 51 40 32 73 15 64 36 69 28 6 17 17 20 62 24 11 65 10 67 6 60 Compressor Assembly Drawing 20 56 39 64 11 7 17 61 1 38 64 59 52 20 AE SHD66DD Owner’s Manual 19645 20884 22183 22186 24304 26025 28855 57195 65746 32 33 34 35 36 37 38 39 20326 20330 20459 29 30 31 28 B PART 0279 0333 0335 0340 0347 0351 0359 0479 052 1 052 3 0525 1554 1556 3 854 4581 4703 5290 5418 5480 7351 8277 1 0 65 9 12813 16711 18611 19589 19592 ITEM 1 2 D 3 4 5 6 7 8 9 10 11 12 13 14 15 C 16 17 18 19 20 21 22 23 24 25 26 27 DE SCR IP T IO N FTG 6-6 MFS-MORB STRAIGHT NUT 0.25-20 HHGR5 NYLOC CAP SCR 0.38-16X1.25 HHGR5 WASHER 0.25 USS FLAT ZINC NUT 0.38-16 HH NYLOC CAP SCR 0.38-16X1.00 HHGR5 CAP SCR 0.50-13X1.50 HHGR5 CAP SCR 0.25-20X0.75 HHGR5 W A S H E R 0 . 25 LO CK WA S H E R 0 . 3 8 LO CK WAS HER 0 . 5 0 L OCK FTG 8-8 MFS-MORB STRAIGHT FT G 8 - 8 M F S- M A O R B 9 0 F TG ST L 4 5 DE G 44- 2 05 N I P PL E 0 . 7 5 X 4 . 00 B R A S S BRKT UNLOADER VALVE MNT SHD66DD WASHER #8 SAE FLAT ZINC ST EL 0.25 90 DEG BRASS 44-161 VALVE CHECK 0.75 STANDARD FTG ST TH ELBOW 45 DEG 12V5OLO FTG ST L 0.25 MNPT/0.125 FNPT SPL C PLR 0 .75 B RAS S GROMMET 1.25ODX0.125X0.625ID FTG 0.75-TEE BRASS 80101-12 SCREW #6-32X0.38 HH MACH SELF TAP NUT SERT 0.25-20X0.38 OD WASHER 0.25 FLAT NYLON BRKT MOTOR MOUNT 19645 POWDERCOAT PLUG 0.25 NPT SQ HD BRASS FTG 0.38-0.25 FF HEX NIPPLE N I P P L E 0 . 3 8 X 8 . 00 B R A S S FTG 12-12X6.00 MP-MP NIPPLE STRAIGHT BRASS SCREW #8-32X0.75 BTNHD SS NU T #8-32 HH NYLOC S S CAP SCR 0.25-20X3.00 BTNHD SS CAP SCR 0.50-13X2.25 HHGR5 HOUR METER 12VDC TST 180-1911 MOTOR HYD RSB04K-Y4500-A 4.0 CID HOSE 0.75(200PSI)-12FFSS SHORT-12FFSS 90 SHORT 11.5 OAL 1 2 2 2 2 1 1 1 4 1 1 1 Q TY. 1 2 2 4 8 10 8 2 2 4 10 1 1 1 3 1 8 1 1 2 1 2 1 1 2 1 7 69515 69643 70144 70385 71406 C0081 C 086 4 C1129 C1180 C2142 C4941 C5662 C5968 C601 5 C6021 C6106 C6353 D0075 D0076 D0786 D0790 D0791 D0792 D0793 D0824 D0840 D0847 D0 8 5 6 D1254 D1266 D1299 D1346 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 42 69516 69514 41 44 69513 40 43 P ART 65873 ITEM DESCRIPTION Q TY. BASE WLDMT SHD66DD ENCLOSURE 1 BULKHD MANIFOLD CPRSR SHD66 BULKHEAD 1 TUBE ASM 0.50 PRESSURE SHD66 1 BULKHEAD YZ TUBE ASM 0.75 RETURN SHD66 BULKHEAD 1 YZ BRKT BULKHEAD MOUNT SHD66 1 TUBE ASM 0.38 DRAIN SHD66 BULKHEAD 1 YZ VALVE SOLND W/ RELIEF 12V SVRV10-26B1 0-N-12DW SHROUD ASM SHD66 BULKHEAD V3 1 FTG HOSE 4-4 PL-MP STRAIGHT BRASS 1 C LAMP 0.50 BLK VINYL 1 S W I T C H P RE S H O B B S 1 COOLER OIL 24 GPM MAX FLOW 1 FTG ADAPT 8-12 F5OLO-S 1 FTG 12-12 MFS-MORB STRAIGHT 1 CLAMP MUFFLER 1 1/8 1 FILTER METAL BOWL 0.25 1 FTG 12-12 MFS-MAORB 90 2 F T G 0 . 75 P L U G 1 2 - P 5 O N 1 CAP SCR 0.25-20X0.75 BTNHD SS 7 NUT 0.50-13 HHGR5 NYLOC 2 WASHER 0 .38 FLAT GR8 8 SCREW #6-32X2.75 RH HD MACHINE 2 NUT #6-32 HH NYLOC 2 BRKT WLDMT COOLER MNT LH SHD66DD 1 WAS H E R 0 .50 F LAT G R 8 12 COUPG 1/4 KW L150-0.75 1 COUPG 3/8 KW L150-1.75 1 COUPG SPIDER L150-U BLUE URETHANE 1 BRKT WLDMT COOLER MNT RH SHD66DD 1 FAN 12.00 PUSH 12 VOLT SPL 301003 1 BRKT 11.00 TWIST 45 DEG SHD66DD 1 B R KT L I F T SH D 6 6 DD 1 CAP 0.38 PIPE HEX 5406-CAP-6 1 FTG 12-12 FP-FP 90 BRASS 1 FTG BULKHEAD 6WLO-WLNL-S 1 CPRSR CHMP R30DHU SPECIAL 1 Compressor Assembly Bill Assembly Drawings 21 22 AE SHD66DD Owner’s Manual Crankcase, Flywheel, Cylinders, & Centrifugal Unloader Crankshaft, Rod, & Piston Assembly Drawings 23 24 AE SHD66DD Owner’s Manual Valve, Manifold, & Filter 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 Assembly Drawings 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 25 26 AE SHD66DD Owner’s Manual Chapter 7: Replacement Parts Replacement Parts Hydraulic Replacement Components Part Number Description 61792 57195 Hydraulic valve Hydraulic motor C1129 C2029 Oil cooler 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 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) 27 28 AE SHD66DD Owner’s Manual Chapter 8: Troubleshooting Troubleshooting 29 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 Compressor will not start: Possible Cause Solution Emergency brake off. Fully engage parking brake. PTO not engaged. Blown fuse. Loose or broken power/ground wire. Compressor runs slow or slows down during operation: Repair connection. Loose air lines or hoses. Tighten air lines and hose connections. Hydraulic motor worn. Replace with new motor. Hydraulic flow too low. Faulty compressor valves. Pilot valve leaking air. Centrifugal unloader valve leaking. Hydraulic oil temp high. Compressor runs hot: Replace fuse. Compressor manifold solenoid will not Repair wiring to coil. Replace valve. engage. Hydraulic relief set too low. Compressor will lock up after operating for a short period: Engage PTO. Check and reset flow. Readjust relief valve. Clean or replace. Replace pilot valve. Remove the governor release valve cap, giving access to the unloader pressure release valve spring and ball - Clean thoroughly and reassembly. Hydraulic fluid low. Hydraulic reservoir size incorrect. Hydraulic motor drive coupler loose. Reposition and tighten coupler. Faulty check valve. Clean or replace check valve. Faulty hydraulic relief valve. Remove relief valve, inspect o-rings and backup seals or replace relief valve. Dirty after cooler or intercooler tubing. Remove and clean. Faulty compressor values. Clean or replace valves. Low crankcase oil level. Add compressor oil as needed. Dirty intake muffler. Clean or replace. 30 AE SHD66DD Owner’s Manual Problem Compressor will not shut down: Possible Cause Solution Misadjustment of pilot valve. Adjust valve per manual specifications. Air line or air hose leaks. Pilot valve leaking air Centrifugal unloader valve is leaking. Moisture or rust contamination. Tighten air lines or hose connections. Clean or replace pilot valve. See “Compressor runs slowly” section. 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. Compressor continues to build air during idle mode: Faulty low pressure intake valve. Compressor will not speed up when compressor is activated: Air reservoir full. Drain air from reservoir. No 12 volt power to coil solenoid valve located on hydraulic manifold. Check fuse. Check ground wires. Check chassis emergency brake switch. Engine RPM will not increase when compressor is activated: Leaking or misadjustment of the pilot valve. Faulty pressure switch. Loose wiring. Faulty pressure switch. Faulty speed control. Compressor cycles or runs often: Faulty pressure switch. Excessive water in air reservoir. Pip lines leaking air. Misadjustment of pilot valve. Air leaking from pilot valve. Check valve leaking. Faulty pressure switch. Chassis engine RPM continue to operate at high Pressure switch wiring. speed when air receiver reaches maximum capacity: Clean or replace low pressure intake valves. Tighten or adjust valve per manual specs. 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. Check wiring to : Solenoid valve, pressure switch, ground wiring. Replace pressure switch. Check speed control wiring for loose or broken connections. Check relay (For ECM operated speed settings.) Replace pressure switch. Drain air reservoir. Tighten or replace lines. Adjust valve per manual specifications. Clean, adjust, or replace. Clean or replace. Replace pressure switch. 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