MAC3001 - Compressor MAKITA - Free user manual and instructions

USER MANUAL MAC3001 MAKITA

Portable Electric Compressor Operating Instructions www.makita.ca NOTICE Carefully read this instruction manual before attempting to operate this compressor. MODEL # MAC3001 SERIAL #

Oil Lubricated Air Compressor MODEL NO. MAC3001 SPECIFICATION CHART Horsepower SCFM @ 40 PSIG SCFM @ 100 PSIG Cut in Pressure Cut out Pressure Bore Stroke Voltage – Single Phase Motor RPM Amperage @ max pressure Tank Size CSA/US Listed

• A circuit breaker is preferred. Use only a fuse or circuit breaker that is the same rating as the branch circuit the air compressor is operated on. If the air compressor is connected to a circuit protected by fuses, use time delay fuses. www.makita.ca IMPORTANT: Read the Safety Guidelines and ALL instructions carefully before operating. MAC3001 www.makita.ca Wear hearing protection. Wear eye protection. Wear respiratory protection. Read the manual.

SAFETY PRECAUTIONS Please familiarize yourself with the following information to prevent damage to your compressor unit and injury to the operator. CAUTIONS The air compressor motor will get hot while in operation. Never touch the discharge tubing, motor or compressor pump while in operation. The compressor operates automatically while the power is connected and turned on. CAUTION Compressed air from the unit may contain hazardous fumes. Air produced by this compressor is not suitable for breathing purposes. Always use a respirator when spraying paint or chemicals, or when sandblasting. Always wear safety glasses or goggles when using compressed air. It is not practical or possible to warn you about all the hazards associated with operating or maintaining this equipment. You must use your own good judgment. WARNING AIR RECEIVER Over pressurizing the air compressor could cause personal injury or material damage. To protect from over pressurizing, a factory pre-set safety valve is installed. NEVER WELD, DRILL OR CHANGE THE AIR

Any replacement parts should be purchased with the same specifications as the original equipment. Please contact the authorized dealer for replacement parts or specifications. SAFETY VALVE This valve is factory installed to prevent over pressurizing of the air receiver. It is factory set at a specific limit for your particular model, and should never be tampered with. Adjustment by user will automatically VOID the warranty.

DO NOT REMOVE, MAKE ADJUSTMENTS TO

OR SUBSTITUTE THIS VALVE!

INSTALLATION & OPERATION EXTENSION CORDS The use of extension cords is not recommended. Plug directly into a dedicated circuit. If the use of an extension cord is unavoidable then make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Table 1 shows the correct size to use depending on cord length and nameplate amperage rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord. Table 1 – Minimum Gauge for Cord Volts Total length of cord in feet Ampere Rating 120V 25ft 50ft 100ft 150ft More Than Not More Than AWG

INSTALLATION Proper care, maintenance and lubrication ensure longevity. The compressor should always be level for proper lubrication. Do not ever tighten foot bolts as excessive vibration may occur. Use only in a clean, dry, and well-ventilated area. The compressor has heat dissipation fins for proper cooling. Keep the fins and other parts that collect dust clean. Do not place rags or other materials on top of the compressor, as this obstructs cooling and can be a fire hazard.

BEFORE OPERATING THE AIR COMPRESSOR

PLEASE CHECK THE FOLLOWING CAREFULLY:

1) Check to see that nuts and bolts are all snug.

2) Check if the quantity and quality of oil is correct.

3) If the intake filters are dirty, they should be replaced or cleaned.

INSTALLATION & OPERATION COMPRESSOR LUBRICATION ALWAYS CHECK THE OIL LEVEL AND QUALITY BEFORE START UP. DO NOT ADD OR CHANGE OIL WHILE THE UNIT

NON-DETERGENT OIL. RECOMMENDED OIL Compressor oil # EAOIL10 (1 Litre) *Compressor originally filled with SAE 20W oil (ISO 68) Compressor oil is a non-detergent mineral oil formulated with additives to help minimize carbon build up, increase ring life and reduce oil consumption, for use at ambient temperatures of 0° to 30° C (32° - 86°F).

Regular mineral oils can also be used in this compressor. Always use nondetergent oil with the following specifications:

1) Remove the oil drain plug. Allow oil to drain completely.

2) Replace the oil drain plug.

3) Refill with the recommended oil to the proper level.

INSTALLATION & OPERATION MAINTENANCE Before doing any maintenance or adjustments to your air compressor, the following safety precautions should be taken: - TURN OFF AND UNPLUG POWER CORD. - DRAIN AIR RECEIVER AND AIR LINES OF AIR PRESSURE.

CHECKING BELT TENSION

Adjust belt(s) so when pressure is applied at the center, there is approx. 1/2" slack (see diagram below). If the belt is installed too tight, the motor might be overloaded. This will cause the motor to overheat. If the belt is installed too loosely, it will slip and excessive wear and vibration will occur. Figure A Centre Too Tight

Slight Bow Correct Too Loose Tension HOW TO INSTALL NEW BELT IF REQUIRED Disconnect power supply. Remove belt guard. Loosen motor bolts and slide motor toward compressor head just enough to allow old belt to be removed. Install proper replacement belt. Slide motor away from compressor head to provide recommended tension as shown in diagram on page 5. Align belt using a straight edge ruler against pulley’s edge. Fasten motor bolts. Ensure motor and compressor pulleys are secure. Re-check alignment. Re-install belt guard and reconnect power supply. Belt tension should be checked after 20 hours of operation. Check tension monthly thereafter.

Check unit for any damage. Check compressor oil level, fill or add if necessary. Pressure switch “Off/Auto” knob should be in “Off” position. Plug in power cord to proper electrical outlet. Stop/Start (pressure switch) control a) Shut-off valve on pilot unloader should be closed (“knurled” knob on top of the pilot unloader should be turned all the way down). b) Turn pressure switch “Off/Auto” switch to “Auto”. Electric motor should now start and fill air receiver(s) with compressed air until cut-out pressure is reached. Compressor should stop and remain stopped until air receiver pressure reaches the cut-in pressure. The unit will continue to cycle in this automatic operation until it is turned off.

6) Continuous run (pilot unloader) control

a) Open the shut-off valve on pilot unloader (“knurled” knob on top of the pilot unloader should be turned all the way up). b) Turn pressure switch “Off/Auto” switch to “Auto”. Electric motor should now start and fill air receiver(s) with compressed air until full pressure is reached. To engage continuous run, turn “knurled” knob down. Your compressor will idle down and continue to idle once maximum pressure is achieved. When cut-in pressure is reached, the unloader valve will de-activate and unit will compress air. The unit will continue in this automatic operation until the unit is stopped (“Off/Auto” switch turn to the “Off” position and/or electric power supply is disconnected).

7) You can switch at anytime from Stop/Start to Continuous Run and vice

versa by opening or closing the valve on the pilot unloader. ELECTRIC DRIVE

1) Check unit for any damage.

2) Check compressor oil level, fill or add oil if necessary.

3) Pressure switch “Off/Auto” switch should be in “Off” position.

4) Plug in power cord to proper electrical outlet. If compressor is not

equipped with a male plug, hire an electrician to install one.

a) Turn pressure switch “Off/Auto” switch to “Auto”. Electric motor should now start and fill air receiver(s) with compressed air until cut-out pressure is reached. Compressor should stop and remain stopped until air receiver pressure reaches the cut-in pressure. The unit will continue to cycle in this automatic operation until the pressure switch is turned to the “Off” position and/or electric power supply is disconnected). MAINTENANCE SCHEDULE EXTRA CARE SHOULD BE TAKEN TO AVOID

¾ Check oil level ¾ Drain condensation from air receiver(s) ¾ Check for any unusual noise or vibration ¾ Be sure all nuts and bolts are tight WEEKLY ¾ Turn off power. Clean dust and foreign matter from cylinder heads, motor, fan blades, intercooler and air receiver(s) ¾ Clean air filter by opening air filter, removing filter element and cleaning it thoroughly with soapy water. Rinse thoroughly and allow to dry completely before assembly. ¾ Worn filters should be replaced ¾ Check V-belts for wear

Inspect unit for leaks Tighten joints if leaks are observed Check V-belt for proper tension Check compressor pulley and motor sheave are aligned and securely fastened (see item 8) QUARTERLY ¾ Inspect the air receiver for corrosion or other damage ¾ Change compressor oil ¾ Replace air filters (more often if compressor is used near paint spraying operations or in dusty environments). TROUBLESHOOTING GUIDE PROBLEM Will not start Low pressure POSSIBLE CAUSE Check power supply Restricted air filter CORRECTIVE ACTION Make sure power is turned Depress motor reset button Replace safety valve Close drain cock Tighten fittings Clean or replace as necessary Replace unloader valve Drain and replace oil Drain oil and fill to proper level Air pressure regulated too high Clean or replace air filter Worn piston rings Replace piston rings Check motor reset button Safety valve leaks Drain cock open Loose tubes or fittings Dirty or plugged air filter Defective unloader valve Oil in discharge Improper oil viscosity Too much oil in the crankcase Compressor overheated

TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE Compressor Overheats Clogged inlet filter Dirty compressor, head, cylinder, intercooler Operating pressure too high Low oil or wrong oil being used Compressor cycle too long, proper cycle is 50 to 60% on Stop/Start operation and 75 to 80% on continuous run operation Leaks in air system Compressor loads and unloads or stops and starts Worn or loose drive belts excessively Pilot valve or pressure switch differential adjustment too close Defective compressor valves Compressor too small for intended use Water in Cycle too short; compressor crankcase, oil does not operate long enough breaking up, oil to vaporize condensed moisture gets dirty, rusty during compression valves or Compressor operating outside cylinder(s) in cold conditions or inlet filter not protected against weather System pressure leaking back through check valve when compressor is stopped Wrong oil being used

CORRECTIVE ACTION Clean or replace as necessary Clean with compressed air Reduce operating pressure Drain and replace oil Allow for longer rest between cycles Replace worn components as necessary Tighten V-belts or replace Make necessary adjustments Replace valves Allow for a longer operating cycle Provide adequate protection against extreme weather conditions Check and replace check valve if necessary Drain and replace with proper oil TROUBLESHOOTING GUIDE PROBLEM Insufficient output, low discharge pressure POSSIBLE CAUSE Clogged inlet filter Drive belts slipping Drain valve left open CORRECTIVE ACTION Clean or replace as necessary Replace worn components as necessary Tension V-belts Close drain valve Defective pressure gauge Replace pressure gauge Leaks in air lines, air valves, fittings, etc… Compressor incorrectly sized Leaking head gasket Dirty or plugged inter cooler tubes Unloader pilot or pressure switch adjustment too low, or defective Worn or defective compressor valves Worn piston, worn out rings Restrictive check valve Motor stalls Compressor knocks Piston rings not seated Faulty unloader/check valve Valves incorrectly installed Drive belts too tight Compressor valves loose or broken Inspect check valve, it may knock at low pressures Compressor not run long enough to seat rings Wrong oil being used, wrong viscosity Replace head gasket Remove and clean inter cooler tubes Make necessary adjustments Replace worn parts Replace worn parts Clean check valve and replace if necessary Replace unloader or check valve Install valves correctly Tension V-belts Check and replace worn or broken valves Remove and clean check valve Allow 100 hours of normal operation for new rings to seat Drain and replace with proper oil

TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE Excessive vibration Loose compressor, motor, or guard Excessive discharge pressure Compressor not level Leg bolts tightened too tightly to floor Wrong oil being used Loose flywheel, drive pulley or drive belts Compressor uses too much oil Worn rods, wrist pin or main bearings Clogged inlet filter Wrong oil being used, wrong viscosity Oil level too high Crankcase breather valve malfunction Compressor operating outside in cold conditions or inlet filter not protected against weather Worn piston rings Piston rings not seated Compressor runs unloaded too long

CORRECTIVE ACTION Tighten components Reduce operating pressure Level compressor Loosen leg bolts Drain and replace with proper oil Tighten loose components and check belts Check and replace worn parts Clean inlet filter or replace if necessary Drain and replace with proper oil Fill compressor with oil to proper level Replace crankcase breather Provide adequate protection against extreme weather conditions Replace piston rings Allow for 100hrs of normal operation for rings to seat Increase load or stop compressor when not needed (check for air leaks)

6389 boul. Couture St. Leonard, PQ H1P 3J5 (514) 323-1223 1-800-361-7049 Saskatchewan 206A-2750 Faithful Ave Saskatoon, SK S7K 6M6 (306) 931-0111 1-888-931-0111 Date Purchased: When you need service: Send complete tool (prepaid) to one of the Makita Factory Service Centers listed, or to an Authorized Makita Service Center. Be sure to attach a letter to the outside of the carton detailing the problem with your tool.

Dealer’s Name and Address: Model No: Serial No: MAKITA WARRANTY

WARRANTY POLICY Every Makita tool is thoroughly inspected and tested before leaving the factory. It is warranted to be free of defects from workmanship and materials for the period of ONE YEAR from the date of original purchase. Should any trouble develop during this one year period, return the COMPLETE tool, freight prepaid, to one of Makita’s Factory or Authorized Service Centers. If inspection shows the trouble is caused by defective workmanship or material, Makita will repair, (or at our option, replace) without charge. This warranty does not apply where: - Repairs have been made or attempted by others; - Repairs are required because of normal wear and tear; - The tool has been abused, misused or improperly maintained; - Alterations have been made to the tool. IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES FROM THE SALE OR USE OF THE PRODUCT. THIS DISCLAIMER APPLIES BOTH DURING AND AFTER THE TERM OF THIS WARRANTY. -The Makita warranty is the only and entire written warranty given by Makita for Makita tools. No dealer or his agent or employee is authorized to extend or enlarge upon this warranty by any verbal or written statement or advertisement. MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,” AFTER THE ONE YEAR TERM OF THIS WARRANTY. This warranty gives you specific legal rights. The provisions contained in this warranty are not intended to limit, modify, take away from, disclaim or exclude any warranties set forth in any provincial legislation. To the extent required by law, the provisions in any provincial or federal legislation with respect to warranties take precedence over the provisions in this warranty. Makita Canada Inc. 1950 Forbes Street Whitby, ON L1N 7B7

NE PAS ENLEVER, ALTÉRER OU

Misc. Description Compressor w/ Flywheel Discharge Tube w/ Fittings Wiring Harness Air Receiver Drain cock V-Belt Belt Guard Electric Motor Pilot Unloader/Check Valve Pressure Switch Motor Pulley Unloader Tube w/ Fitting Safety Valve Handle Grip Vibration Damper Pneumatic Wheel Axle Power Cord w/ Plug Regulator Regulator Gauge Coupler Tank Gauge Triple Manifold Block Control Panel 1/8” NPT Elbow (for coupler) ¼” NPT Elbow (for Regulator) Regulator Hose (Yellow) Part # PV01A TU-15-AL 12/3-42-TT50 8TT35X5-M IH1850 4L530 BGC

PV01A “C” INCLUDES RINGS + 5, 8, & 16 “B” INCLUDES PARTS 5, 6, & 8 “D” INCLUDES PARTS 3, 4, & 6 Item

crankcase to rear bearing housing gasket 51121-4704

rear bearing housing 51121-4703

connecting (interstage) tubing 51121-7710

Misc. 1/4" street elbow (oil drain) Misc. rear bearing snap ring Misc. interstage "Y" fitting 51121-7710

interstage "elbow" fitting Intake filter element kit includes one (1) intake filter element Valve repair kit includes: Valve seat to head gasket (item 5) Two(2) outlet valve plates (item 6) Intake valve plate (item 7) Six(6) valve plate screws Valve seat to cylinder gasket (item 8) Ring repair kit includes: Valve seat to head gasket (item 5) Valve seat to cylinder gasket (item 8) Two(2) compression rings One(1) oil control ring Cylinder to crankcase gasket (item 16) Valve plate assembly (not shown) 51112-7701