Rolair GD5000PV5H - PORTABLE AIR COMPRESSOR Manual

INTRODUCTION

With over 50 years experience building ROLAIR air compressors specifically designed for the professional, Associate Engineering Corporation has earned a reputation for providing a product unsurpassed in quality and reliability. We are committed to continuing this tradition by analyzing and adapting to the changing needs and rigorous demands of your industry. You can depend on ROLAIR because they are built to last.
This manual was compiled for the benefit of the operator. Do not use or allow anyone else to use your air compressor until this manual is read and all safety/operating instructions are understood. By reading and following the instructions contained in this manual, you can achieve years of trouble free service from your new air compressor. If you have any additional safety or operating questions after reading this manual, please contact your distributor or our customer service department. Do not remove or paint over any of the warning decals attached to the compressor. If any warning decal is missing or unable to be read, discontinue use and contact us for a free replacement (1-800-310-3573).

SYSTEM CONTROLS

1. SAFETY-RELIEF VALVE
   Every ROLAIR air compressor is equipped with a safety-relief valve which is designed to discharge tank pressure at a predetermined setting when a systems failure occurs. Check the safety valve daily by pulling on the ring only when the tank pressure is completely drained. The spring loaded valve should move freely within the safety valve body. An inoperable safety valve could allow an excessive amount of tank pressure to build causing the air tank to violently rupture or explode.
   Do not tamper with or attempt to eliminate the safety relief valve.
2. REGULATOR – WORKING PRESSURE
   To adjust the output/line pressure, simply lift up on the regulator adjustment knob and rotate clockwise to increase working pressure or counterclockwise to decrease. Push adjustment knob back down to lock in setting. Never exceed the manufacturer's maximum allowable pressure rating of the tool being used or item being inflated.
3. PRESSURE GAUGE(S)
   Typically, most compressors are designed with a gauge to measure tank or storage pressure and another gauge attached to the regulator that indicates output or working pressure
4. DRAIN VALVE(S)
   One or more drain valves are installed to allow moisture to be drained on a daily basis from the compressor storage tank(s). Open drains carefully and slowly to prevent scale, rust, or debris from becoming expelled at a high rate of speed. Open drain valve and allow the motor and pump to run unloaded for a minute to warm up.
5. AIR INTAKE FILTER
   Air intake filters are installed to prevent foreign matter from entering the engine or compressor pump. Check intake elements on a regular basis and either clean or replace as needed. Warm soapy water or low compressed air may be used to clean the elements. Check intake canisters or elbow components for cracks or broken seals and replace if structural problems are found.
6. CHECK VALVE
   Every ROLAIR air compressor is built with a check valve to seal off and maintain tank pressure after the top end pressure setting of pilot valve or pressure switch is reached. The check valve works in conjunction with the pressure switch relief valve to provide a loadless start for the compressor system. A quick burst of air escaping from the pressure switch relief valve after an electric unit reaches top end indicates the check valve is working properly. If the compressor has a mysterious leak after stopping that cannot be traced elsewhere, the check valve may require servicing/replacing.
7. VIBRATION DAMPENER(S)
   The rubber pads installed beneath every portable ROLAIR tank assembly are very important to the proper operation of the air compressor. They provide protection from vibration that left unchecked could cause damage to many system components.
8. QUICK DISCONNECT
   A universal or 3-way quick disconnect is installed on your air compressor. Simply push a 1/4" male plug into coupler to snap hose fitting into coupler. Always relieve pressure from coupler before installing or removing hose. See instructions for regulator (#4 above). Pull back on collar to remove air hose after pressure is relieved

9. DIPSTICK
   Prior to daily operation, make a habit of checking the oil level of the compressor pump and engine (if compressor is gas powered). Every direct-drive hand-carry air compressor has a dipstick to help check and maintain the proper oil level. The dipstick also functions as a crankcase vent. Never operate a direct-drive unit without the factory-supplied dipstick.
10. PILOT-UNLOADER VALVE
    A pilot-unloader valve is used on all gas-powered units and can be used on electric air compressors to operate in a continuous manner. When the storage tank reaches the top pressure setting of the pilot valve, the air being compressed is discharged to atmosphere instead of into the storage tank. When the tank pressure drops to the low pressure setting of the pilot valve, the compressed air will be redirected to the air tank. Do not attempt to replace the pilot valve without first draining the tank pressure completely. See Figure 3 for adjustment and fine-tuning instructions. Do not adjust above the following factory recommendations.
11. AUTOMATIC-IDLE CONTROL
    Every ROLAIR gas-powered air compressor is built with an engine idle control kit that automatically decreases the engine speed when the top end pressure setting of the pilot unloader valve is reached. The top RPM setting of the engine is factory set for maximum performance and service life. Do not alter the factory top RPM setting. The engine idle speed is factory set and controlled by a black plastic Philips head screw on the carburetor. A slight increase to the idle speed setting may be required when operating in colder temperatures. Turn screw clockwise in 1/4 turn increments to increase the idle speed. If the idle speed setting is too low, premature fouling of spark plug will occur.
12. ENGINE KILL SWITCH
    A kill switch is installed to easily stop the engine. Do not attempt to move the throttle lever (as described in the Honda owner's manual) when stopping the engine. The engine throttle lever is factory set and locked down at a top RPM setting that will provide maximum performance and service life for the complete air compressor system. The kill switch must be moved to the "On" position prior to pulling the recoil rope assembly to start the engine.
13. ENGINE CHOKE
    Moving the choke lever completely to the left (closed position) will help start a cold engine. Also see instructions for cold-start valve (Item #4). After start up, the choke lever must be moved completely to the right (open position) for the engine to operate properly. Fouling of spark plug and excessive internal carbon build up will occur if engine is operated with choke lever even partially closed.
14. FUEL SHUT-OFF VALVE
    The fuel shut-off valve should only be moved to the "Open" position (completely to the right) when the engine is being operated. Always stop the flow of fuel by moving the shut-off valve completely to the left when the engine is not being operated. Do not move or transport the air compressor with the fuel valve in the open position.

PRE-START CHECKLIST

Read the owner's manual thoroughly. Make sure that you completely understand all of the safety warnings, system controls and instructions provided before attempting to operate this air compressor. Every effort has been made to provide you with the information needed to obtain many years of reliable and trouble-free service out of your new air compressor. It is your responsibility to operate the air compressor properly. To obtain the longest possible service life from your air compressor you must always keep the following instructions in mind.

1. ALWAYS OPERATE THE COMPRESSOR IN A LEVEL POSITION
   All splash-lubricated pumps have a dipper on the bottom of the connecting rod that must remain submerged in the oil bath. Operation at more than a 10 degree angle will cause the pump to seize and void the product warranty
2. OPERATE IN A CLEAN, DRY AND WELL VENTILATED AREA
   Allow at least 18" behind the belt guard for proper cooling of pump from flywheel blast. Do not operate in the rain or in areas of standing water. Never operate in an area where other gases, fumes or vapors are present which may become explosive when compressed. Do not operate compressor in an enclosed area.
3. CHECK OIL LEVEL DAILY AND CHANGE AT REGULAR INTERVALS
   Refer to the maintenance section of this owner's manual for the correct type/weight of oil to use and how often the oil should be changed. Check oil levels daily.
4. INSPECT/CLEAN/CHANGE INTAKE ELEMENTS ON A REGULAR BASIS
   The ingestion of dirt into the pump and engine is the primary cause of premature wear. Pay special attention to the intake filters. Check intake filters daily.
5. CHECK TENSION OF BOLTS AND HARDWARE ON A REGULAR BASIS
   Operation of any equipment with loose bolts and/or fittings will lead to excessive vibration and the premature failure of the compressor system control components.
6. MAINTAIN RUBBER VIBRATION PADS
   Excessive vibration is a major cause of premature compressor failure. Always maintain the rubber vibration pads located beneath tank assembly. Operation without them will void your warranty.
7. DRAIN MOISTURE FROM AIR TANKS DAILY
   Water is a natural byproduct of compressed air. Drain air tank(s) after each use to combat internal tank corrosion. Keep drain valve(s) closed if storing compressor for any length of time.
8. DO NOT ALTER FACTORY RPM SETTINGS ON GAS-POWERED COMPRESSORS.
   Engine throttle arm is factory set and locked into position at RPMs that will provide maximum performance, fuel consumption and service life. Alterations to this setting will void your warranty.

SPECIFICATIONS

OPERATION

Your safety and the wellbeing of others during the operation of every ROLAIR compressor is our main concern. Do not operate or permit anyone else to operate your air compressor until the information contained in this manual is read and completely understood. Please contact your distributor or our customer service department if you have any questions on the proper use of your air compressor.
WET CONDITIONS: Do not operate your compressor in damp or wet conditions, or after it has been exposed to rain/sleet/ice/snow or moisture of any kind. Failure to follow this warning could lead to electric shock and/or rust and ice forming on critical components, making the compressor dangerous to operate. Always operate and/or store compressor in a clean, dry location with good ventilation.

GAS POWERED
Refer to item numbers 11, 12, 13 and 14 in the "System Controls" section of this manual for information on the engine automatic idle control, kill switch, choke and fuel shut-off valve. Also note the engine throttle arm is locked into a top RPM setting that will provide maximum service life and does not need to be moved to start or stop the machine. Additional instructions can be found in the engine owner's manual. Use the drain valve located on the pump aftercooler or intercooler for cold-starting purposes. Take additional care to keep dirt/debris from entering the fuel tank or obstructing the air flow through the engine or past the pump. Make sure the air flow to the regulator is completely closed (gauge attached reads 0 PSI) before attaching air hose and accessory. A slight hissing noise caused by the air flow being directed to atmosphere during engine idle is normal. Store compressor in a warm/dry location and perform maintenance as indicated in your manuals.

FREEZING TEMPERATURES:
Proper fluid maintenance and warm up procedures are mandatory before attempting to start or operate an air compressor in freezing temperatures. Water, a natural byproduct of compressed air, could turn into ice and potentially block air flow into, though, and/or out of the pump, air tank(s), and air line(s). Drain air tanks/ lines after every use and leave drain valves open when not in use.
If all, or part, of the compressor may be frozen, you must completely thaw the compressor before attempting to start. Gradually increase the temperature above freezing and then drain moisture from the air tanks, intercoolers, and water traps.
Cold Weather Best Practices:

• Do not attempt to start a frozen compressor. Thaw completely first.
• Store your air compressor in a clean, dry area that stays consistently above freezing temperatures.
• Change the oil in the pump and engine to winter grade (check owner's manual).
• Prior to starting, open the tank drain(s) and allow the compressor to run for 45-60 seconds with the tank drain(s) open before closing to build tank pressure.
• Using a lubricator with de-icing fluid may also be needed to keep your air lines from freezing up/blocked by ice.
• Contact your ROLAIR dealer or our factory customer service department if you have additional questions.

HIGH-ALTITUDE OPERATION:
Due to a decrease in atmospheric pressure air compressor pumps produce less CFM at higher elevations. As a rule of thumb the output will decrease approximately three percent per 1000 feet of elevation. Also, because air at higher elevations is less dense and does not cool as well, electric motors cannot be subjected to the full nameplate service factor amp rating and may need to be upgraded to avoid repeated overheating.
Direct drive or hand-carry compressors built with cold-start valves may need to be modified when operated in higher elevations. Carburetors on gas-powered air compressors may also need to be rejetted to perform properly at higher elevations. Contact our factory Customer Service Department if your normally reliable air compressor fails to operate correctly at higher elevations.

MAINTENANCE

Your new air compressor represents the finest engineering and construction available. Even the best machinery requires periodic maintenance. Please stick to the maintenance schedule and consider the suggestions that follow to keep your compressor in peak condition.
NOTE: Always unplug or shut down your compressor and drain the air tanks completely before attempting any type of maintenance. Wait for compressor to cool before servicing.

Replace the oil after the first 50 hours of operation.

MAINTENANCE HINTS:

1. Use a soap/water solution to check for air leaks.
2. Never clean filters with a flammable solvent.
3. Retorque head bolts only after pump has cooled.
4. Never weld on air tank(s).
5. Use heat to loosen Loctite seal on drain valves, engine pulleys, and flywheels before attempting to remove.

LUBRICATION
Prior to each use, make a habit of checking the pump oil level. Most direct-drive air compressors have a dipstick with casting marks that indicate the minimum and maximum acceptable levels of oil. Always maintain the oil level at the maximum mark on the dipstick or to 2/3 full in the sight gauge
Do not operate the pump with an inadequate or excessive amount of oil. The cost of failures which occur due to incorrect oil levels will not be covered under warranty.
DO NOT USE A DETERGENT OIL!
NOTE: Unit must be level when in operation

OIL CHART

• ROLAIR Standard 10 WT or 30 WT Should be changed every 200-400 hours after the break-in period
• ROLAIR Semi-synthetic should be changed every 1,000 - 2,000 hours
• ROLAIR Full-synthetic should be changed every 2,000 - 4,000 hours.

MAINTENANCE SCHEDULE

TORQUE CHART (INCH/LB)

PILOT VALVE ADJUSTMENT
NOTE: Should only be performed by ROLAIR factory authorized personnel.

RESETTING DIFFERENTIAL (2)
Make sure the top toggle lever is positioned as shown. (See Figure 3). Loosen locknut (1) by turning counterclockwise several full turns. Gently turn differential setting (2) clockwise only until the internal rod makes contact with the steel ball inside. After making contact, turn differential (2) counterclockwise 1/4 turn. Secure position by tightening locknut (1) and proceed to top end setting.

TOP-END SETTING (4)
Loosen locknut (3) by turning counterclockwise several full turns. (4) is the top end setting. Turning (4) clockwise will increase the top end pressure setting. Turning counterclockwise will decrease the top end pressure setting. Begin at a low setting by turning counterclockwise one full turn. Proceed to fine tuning instructions.

FINE-TUNING INSTRUCTIONS
Start engine/motor and observe tank pressure gauge. As tank pressure approaches 100-130 P.S.I.G., the pilot valve should begin unloading at felt muffler and cause gas engine to slow down to idle speed. If pilot valve does not unload as tank pressure approaches 130 P.S.I.G., slowly turn top end setting (4) counterclockwise until pilot starts to unload prematurely (at 100 P.S.I.G.), turn top end setting (4) clockwise in 1/4 turn increments, tap down on the internal rod at toggle attachment and repeat until desired top end setting is reached. If pilot valve begins to rifle (sputter), fine tune differential setting (2) 1/16 turn in either direction until rifling stops. After fine tuning, secure setting by turning locknuts (1 & 3) clockwise until tight. Hold setting (2 & 4) in place while turning locknuts to secure.

NOTE: Engine RPM's (High – Low Settings) are factory set for maximum efficiency. Adjusting RPM's above factory specification will void the warranty.

TROUBLESHOOTING

Make sure you completely understand all of the safety warnings and operation of each system control component before attempting any maintenance or repair. Always drain the tank pressure completely, make sure the power cord is unplugged, and unit has time to cool before performing any maintenance or service operations.

PARTS

Genuine ROLAIR replacement parts are sold nationwide through a network of authorized dealers and service centers. Please contact the dealership where your air compressor was purchased or our factory Customer Service Department if you need help troubleshooting, obtaining parts, or locating an authorized ROLAIR service representative.
To order replacement parts:

1. Give compressor model number
2. Give compressor serial number
3. Name of part
4. Part number
5. Quantity required

RECORD OF PERTINENT INFORMATION
Make a permanent record of the model and serial number of your new air compressor here. You'll save time and expense by including this reference information when requesting service or replacement parts.