MAC5500G - Compressor MAKITA - Free user manual and instructions

USER MANUAL MAC5500G MAKITA

Portable Gas Compressor Operating Instructions www.makita.ca NOTICE Carefully read this instruction manual before attempting to operate this compressor. MODEL # MAC5500G SERIAL # MAC5500G

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 and engine will get hot while in operation. Never touch the discharge tubing, engine or compressor pump while in operation. The compressor operates automatically while the engine is running. 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. WARNING 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. AIR RECEIVER Over pressurizing the air receiver 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

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,

OR SUBSTITUTE THIS VALVE!

INSTALLATION & OPERATION INSTALLATION Proper care, maintenance and lubrication ensures longevity. The compressor should always be level for proper lubrication. 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:

Check to see that nuts and bolts are all snug.

Check if the quantity and quality of oil is correct.

If the intake filters are dirty, they should be replaced or cleaned. COMPRESSOR LUBRICATION

ALWAYS CHECK THE OIL LEVEL AND

• 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°F - 86°F).

INSTALLATION & OPERATION OTHER APPROVED OILS. Regular mineral oils can also be used in Makita compressors. Always use a non-detergent oil with the following specifications:

Remove the oil filler plug

Slowly pour the proper oil into the pump crankcase.

Always keep oil level in the middle of the sight glass. OIL CHANGES INITIAL OIL CHANGE DUE AT 100 HOURS.

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

Replace the oil drain plug.

Refill with the recommended oil to the proper level. ENGINE LUBRICATION Check engine Owner’s manual for lubrication and maintenance requirements. MAINTENANCE Before doing any maintenance or adjustments to your air compressor, the following safety precautions should be taken:

DRAIN AIR RECEIVER AND AIR LINES OF AIR PRESSURE. INSTALLATION & OPERATION

CHECKING BELT TENSION

Adjust belt(s) so when pressure is applied at the center, there is approximately 1/2” slack (see diagram “Figure A” below). If the belt is installed too tight, the engine might be overloaded. This will cause the engine to overheat. If the belt is installed too loosely, it will slip and excessive wear and vibration will occur. Figure A Centre Distance Too Tight Slight Bow Correct Tension Too Loose HOW TO INSTALL A NEW BELT IF REQUIRED:

Turn off engine. Wait until engine is completely stopped

Loosen engine bolts and slide engine toward compressor head just enough to allow old belt to be removed.

Install proper replacement belt.

Slide engine away from compressor head to provide recommended tension as shown in diagram (Figure A.)

Align belt using a straight edge ruler against pulley’s edge.

Fasten engine bolts.

Ensure engine and compressor pulley’s are secure. Re-check alignment.

Re-install belt guard.

10) Belt tension should be checked after 20 hours of operation.

Check tension monthly thereafter.

Check entire unit for any damage.

Check compressor and engine oil level, fill or add if necessary.

Make sure gas tank is filled.

Read entire engine manual.

Starting the engine.

Move fuel lever to the “On” position. - If engine is cold, move choke lever to the “Closed” position - If engine is warm, leave choke lever in “Open” position

Turn engine switch to “On” position.

Pull starter grip lightly until you feel resistance, then pull briskly, return starter grip gently - engine should start, if not repeat.

Once the engine starts running, slowly move the choke lever to the “Open” position.

With the engine running properly, the compressor fills the air receiver with compressed air, when maximum pressure (set by the pilot valve control) is reached, the engine and compressor will slow down to idle speed, and will return to full RPM when the cutin pressure is reached. The unit will continue to cycle automatically until turned off.

Stopping the engine.

Turn engine switch to the “Off” position.

Turn the fuel lever to the “Off” position. Engine idle speed may need to be adjusted, even on your brand new unit to compensate for differences in altitude. Please consult the engine operating manual.

MAINTENANCE SCHEDULE Extra care should be taken to avoid personal injuries with automatically controlled compressors

Drain condensation from air receiver.

Check for any unusual noise or vibration.

Be sure all nuts and bolts are tight. WEEKLY

Turn off ENGINE. Clean dust and foreign matter from cylinder head, ENGINE, fan blades, intercooler and air receiver.

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.

Worn filters should be replaced.

Check v-belts for wear. MONTHLY

Inspect unit for leaks.

Tighten joints if leaks are observed.

Check v-belts for proper tension.

Check compressor pulley and ENGINE sheave are aligned and securely fastened. QUARTERLY OR 300 HOURS (Whichever comes first)

Inspect the air receiver for corrosion or other damage.

Change compressor oil.

Replace air filter (more often if compressor is used near paint spraying operations or in dusty environments).

TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Will not start Please refer to Honda manual included Low pressure Safety valve leaks. Replace safety valve. Oil in discharge Compressor overheats Drain cock open. Close drain cock. Loose tubes or fittings. Tighten fittings. Dirty or plugged air filter. Clean or replace as necessary. Defective unloader valve. Replace unloader valve. Too much oil in the crankcase. Drain oil and fill to proper level. Improper oil viscosity. drain and replace oil Compressor overheated. Air pressure regulated too high. Restricted air filter. Clean or replace air filter. Worn piston rings. Replace piston rings. Dirty compressor head, cylinder or intercooler. Clean with compressed air. Clogged inlet filter. Clean or replace as necessary. Operating pressure too high. Reduce operating pressure. Low oil or wrong oil being used. Drain and replace oil. Compressor cycle too long. Proper cycle is 50-60% on Stop/Start operation. Allow for longer rest between cycles. Compressor Pilot valve differential adjustloads & uned too close. loads or idols up & down excessively Leaks in air system.

Replace worn components as necessary. Make necessary adjustments. Check for leaks. Worn or loose drive belts Tighten V-belts or replace Defective compressor valves. Replace valves. Compressor too small for intended use. Upgrade to larger compressor. TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Insufficient output, low discharge pressure Clogged inlet filter. Clean or replace as necessary. Leaks in air lines, air valves, fittings, etc... Replace worn components as necessary. Drive belts slipping. Tension V-belts. Drain valve left open. Close drain valve. Defective pressure gauge. Replace pressure gauge. Leaking head gasket. Replace head gasket. Dirty or plugged inter cooler tubes. Remove and clean inter cooler tubes. Unloader pilot adjusted too low, or defective. Make necessary adjustments. Worn or defective compressor Replace valves. valves. Worn piston, worn out rings. Replace worn parts. Restrictive check valve. Clean check valve and replace if necessary. Compressor incorrectly sized. Upgrade to larger compressor. Engine stalls. Faulty unloader / check valve. Replace unloader check valve. Water in crankcase oil gets dirty, rusty valves or cylinders Low oil in engine Add oil to engine Compressor not level. Level compressor. Cycle too short; compressor Allow for longer operating does not operate long enough cycle. to vaporize condensed moisture during compression. Compressor operating outside in cold conditions or inlet filter not protected against weather. Provide adequate protection against extreme weather conditions.

TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION System pressure leaking back Check and replace check through check valve when valve if necessary. compressor is stopped. Excessive vibration Compressor Knocks Compressor uses too much oil

Wrong oil being used. Drain and replace with proper oil Loose compressor, engine or engine guard. Tighten components. Compressor not level. Level compressor Leg bolts over tightened to floor. Loosen leg bolts. Excessive discharge pressure. Reduce operating pressure. Wrong oil being used. Drain and replace with proper oil. Loose flywheel, drive, pulley or drive belts. Tighten loose components and check belts. Worn connector rods, wrist pin or main bearings. Check and replace worn parts. Compressor valves loose or broken. Check and replace worn or broken valves.. Check valve knocks at low pressure. Remove and clean check valve. Clogged inlet filter. Clean inlet filter or replace as necessary. Wrong oil being used, wrong viscosity. Drain and replace oil. Oil level too high. Fill compressor with oil to proper level. Crankcase breather valve malfunction. Replace crankcase breather. Compressor runs unloaded too long Increase load or stop compressor when not needed. Check for air leaks. TROUBLE SHOOTING PROBLEM Piston rings not seated. POSSIBLE CAUSE CORRECTIVE ACTION Compressor operating outside in cold conditions or inlet filter not protected against weather. Provide adequate protection against extreme weather conditions. Worn piston rings. Replace piston rings. Piston rings not seated. See below. Allow 100 hours of normal operation for new rings to seat.

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 the 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 IMPLIED 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 of federal legislation with respect to warranties take precedence over the provisions in this warranty. Makita Corporation 3-11-8, Sumiyoshi-cho, Anjo, Aichi 446-8502 Japan Makita Corporation of America 2650 Buford Hwy. Buford GA 30518 Makita Canada Inc 1950 Forbes Street Whitby, ON L1N 7B7

NE PAS ENLEVER, ALTÉRER OU

Pneumatic Wheel / axle

Pulley Bushing - Engine LX3/4-E

Discharge Tube w/ Fittings

Compressor w/ Flywheel A49-E

Regulator Gauge 411029-E

Triple manifold block CPL-MAN-E

Valve seat to head gasket 52122-2105-E

Intake valve plate 52122-2103-E

Valve seat to cylinder gasket 52122-2104-E

Crankcase to rear bearing housing gasket 51122-4704-E

Rear bearing housing 51122-4703-E

Oil seal 51122-4708-E

Front bearing housing 51122-4706-E

Crankcase to front bearing housing gasket 51122-4707-E

Connecting (interstage) tubing 51122-7710-E

Misc 1/4” street elbow (oil drain) (Not Shown) Misc Rear bearing snap ring (Not Shown) Misc Interstage “Y” fitting (Not Shown) Misc Interstage “elbow” fitting (Not Shown) 51112-7701-E

Intake filter element kit includes: three (3) intake filter elements 101000-300-E

Valve repair kit includes: 101000-165-E

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)

4) Most favored points are / Points favoris sont: