Puma DD2022S Use and Care Manual
Contents
1. 1 1 Remove the oil filler plug 1 2 Slowly pour the proper oil into the pump crankcase 1 3 Always keep oil level between the marks up and low level on the oil dipstick or on the red circle on the sight glass UP LEVEL CHECK FOR PROPER OIL LEVEL ON DIPSTICK LOW LEVEL 6 2 CHANGE THE OIL 6 2 6 2 6 2 Change oil after the first 8 hours of compressor operation gt then change oil after every 300 working hours or 3 months whichever comes first 1 Remove the oil drain plug gt allow oil to drain out 2 Replace the oil drain plug gt the use of a sealing compound or Teflon tape to avoid leakage is recommended 3 Refill with the recommended oil to the proper level 7 INITIAL START UP PROCEDURE Do not attempt to operate the air compressor unit without first checking the oil level in the pump add oil as required Serious damage may result from use without oil 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 10 7 11 7 12 7 13 Check to see that nuts and bolts are all snug this must be down as some fasteners may become loose in transit Check that proper type and level oil is correct gt see page for proper compressor lubrication Check that compressor is on a strong stable level base Check that oil breather is clean Check that air filter is clean Do not place any materials on or against the belt guard gt or the compressor unit it2. gt damage may result in transit and cause problems in compressor operation GENERAL REQUIREMENT It is your responsibility to ensure air compressor is installed correctly as well as maintained and serviced on a regular basis Information has been included in this booklet outlining the suggested air compressor maintenance schedules and a trouble shooting guide It is important that you read this information and keep it in a safe place for future reference INSTALLATION Located the compressor in a clean dry and well ventilated area gt The compressor should be located 12 18 inches from a wall or any other obstruction that would interfere with the air flow through the cooling function Place the air compressor on a firm and level surface gt The air compressor is designed with heat dissipation fins that allow for proper cooling gt Keep the fins and other parts that collect dust or dirt clean gt A clean compressor runs cooler and provides longer service Allow room for easy access to the air compressor for maintenance and service work I DO NOT EXPOSE DO NOT PLACE TO RAIN AREA IN INCLINED PLANE DO NOT PLACE INA NARROW SPACE DO NOT PLACE IN A WETAREA 5 5 2 3 PRESSURE SWITCH PLACE IN A CLEAN DRY AND WELL VENTILATED AREA 5 2 ELECTRICAL It is your responsibility to ensure that the air compressor is electrically connected in a safe and correct manner Any electrical work should be carried o
3. with all local cades If these grounding instructions are not completely understand gt or if in doubt as to whether the compressor is properly grounded gt have the installation checked by a qualified electrician 115V 230 Grounded outlet box Xe Se bes Grounded outlet Plug N 7 Y Plug Grounding pin 5 2 5 1 This product is for use on a nominal 115 or 230 volt circuit A cord with a grounding plug 5 2 6 as shown here shall be used gt Make sure that the product is connected to an outlet having the same configuration as the plug gt No adapter should be used with this product EXTENSION CORDS The use of any extension cord will cause some drop in voltage and loss of power For optimum performance gt plug the compressor power cord directly into a grounded wall socket Do not use an extension cord unless absolutely necessary It is better to use a long air hose to reach area where work is being performance If use of an extension cord can not be avoided gt refer to the following guidelines before using cordially Use only 3 wire extension cord Make sure your extension cord is in good condition Be sure gauge is sufficient to carry the current the unit the unit will draw The smaller the gauge the heavier the cord 6 COMPRESSOR LUBRICATION Do not add or change oil while the compressor is in operation use the recommended SAE10 30W no n detergent oil only 6 1 Filling the oil 6 6 6
4. AIR COMPRESSOR OPERATING INSTRUCTION AND PARTS LIST DIRECT TYPE IMPORTANT PLEASE MAKE CERTAIN THAT THE PERSON WHO IS TO USE THIS EQUIPMENT CAREFULLY READS AND UNDERSTANDS THESE INSTRUCTIONS BEFORE STARTING OPERATIONS Record these numbers in the space below and retain for future reference Type Model No Serial No TABLE OF CONTENTS 1 IMPORTANT SAFETY INSTRUCTION 2 GENERAL DESCRIPTION 3 ON RECEIPT INSPECTION 4 GENERAL REQUIREMENT 5 INSTALLATION 6 COMPRESSOR LUBRICATION 7 INITIAL START UP PROCEDURE 8 MAINTENANCE CHECK LIST 9 STORAGE 10 TROUBLE SHOOTING PAGE 3 4 10 11 1 IMPORTANT SAFETY INSTRUCTION IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE READ AND UNDERSATND ALL INSTRUCTIONS BEFORE INSTALLING OR USING YOUR AIR COMPRESSOR UNIT gt IT CONTAINS VALUABLE INFORMATION THAT WILL HELP YOU IN THE SAFETY INSTRUCTION RECEIVING gt INSTALLATION gt USE AND MAINTENANCE OF THE UNIT gt KEEP THIS BOOKLET IN A SAFE PLACE FOR FUTURE REFERENCE 1 1 RISK OF FIRE DO NOT SPRAY COMBUSTIBLE OR FLAMMABLE LIQUID IN A CONFINED AREA gt SPRAY AREA MUST BE WELL VENTILATED DO NOT SMOKE WHILE SPRAYING OR SPRAY WHERE SPARK OR FLAME IS PRESENT ARC PARTS KEEP COMPRESSOR AT LEAST 12 18 INCHES AWAY FROM SPRAYING AREA AND ALL EXPLOSIVE VAPORS 1 2 RISK OF ELECTRICAL SHOCK DISCONNEC
5. POSITION ALWAYS OPERATE COMPRESSOR IN A STABLE POSITION TO PREVENT ACCIDENTAL MOVEMENT OF THE UNIT o 4 2 5 5 1 MECHANICAL GENERAL DESCRIPTION OF AIR COMPRESSOR To compress air the piston move up and down in the cylinder gt During the down stroke gt air is drawn in through the inlet valve The discharge valve remains closed gt On the up stroke of the piston gt air is compressed The inlet valve closes and compressed air is forced out through the discharge valve through the check valve and into air receiver tank Working air is not available until the compressor has raised the air receiver pressure above that required at the air service connection The air inlet filter openings must be kept clear of obstructions Your air compressor can be used for operating paint spray tools caulking guns grease guns air brushes sandblaster or inflating tires and plastic toys spraying weed killer and insecticides etc An air regulator is usually necessary for most of these application ON RECEIPT INSPECTION Each PUMA air compressor outfit is carefully factory tested and inspected before shipment Every attempt is made to ensure safe and complete shipment of our products It is the responsibility of the receiver of the goods to ensure the products has been shipped in full and arrival in suitable condition to avoid expenses being incurred to correct such problems With improper handling
6. T COMPRESSOR FROM ELECTRICAL SUPPLY CIRCUIT BEFORE SERVICING DO NOT EXPOSE COMPRESSOR TO RAIN OR OPERATE IN A WET AREA 2 uly NEVER USE THE AIR COMPRESSOR WITHOUT CONNECTION TO A PROPERLY sr GROUNDED OUTLET WITH THE SPECIFIED VOLTAGE AND FUSE PROTECTION THE COMPRESSOR MUST BE LOCATED A MINIMUM OF 12 18 INCHES FROM ANY SOURCE OF POTENTIALLY EXPLOSIVE VAPOURS IMPROPER GROUNDING CAN RESULT IN ELECTRICAL SHOCK gt 1 3 RISK OF EXPLOSION DRAIN TANK DAILY gt CONDENSED WATER WILL CAUSE RUSTING AND RISK OF TANK RUPTURE OR EXPLOSION DO NOT REPAIR gt MODIFY OR WELD TANK RETURN TO AUTHORIZED SERVICE CENTER IF REPLACEMENT IS REQUIRED DO NOT ADJUST REGULATOR TO RESULT IN OUTPUT PRESSURE GREATER THAN MARKED MAX PRESSURE OF ATTACHMENT PRESSURE SWITCH IS SET AT THE FACTORY FOR OPTIMUM PERFORMANCE OF YOUR PARTICULAR MODEL NEVER BYPASS OR REMOVE PRESSURE SWITCH AS SERIOUS DAMAGE TO EQUIPMENT OR PERSONAL INJURY COULD RESULT FROM TOO HIGH OF PRESSURE BEFORE STARTING COMPRESSOR gt PULL SAFETY VALVE RING TO MAKE SURE THE VALVE MOVES FREELY THE SAFETY VALVE IS FACTORY INSTALLED TO PREVENT THE AIR RECEIVER FROM DAMAGE SHOULD MALFUNCTION OCCUR IN THE PRESSURE SWITCH gt IT IS FACTORY SET AT A SPECIFIC LIMIT FOR YOUR PARTICULAR MODEL gt AND SHOULD NEVER BE TAMPERED WITH ADJUSTMENT BY USER WILL AUTOMATICALLY VOID WARRANTY 1 4 RISK OF BURNS HOT SURFACE CAN CAUSE SERIOUS INJURY
7. compressor oil Clean piston Check cylinder walls or scoring Replace main bearings Compressor over heating on BR WwW NY Undersized unit for air requirements Compressor location Air leaks in the system Restricted air filter Improper grade or level of oil Worn damage gt or carbon build up on valve Carbon build up at after cooler tube check valve a A N N O Contact PUMA compressor distributor See installation section Fix leaks Clean or replace filter Replace with SAE10W 30 non detergent compressor oil Clean gt repair or replace valves Clean or replace Pressure switch unloading does not function or leak air when Pressure switch unloading may be dirty or faulty Clean gt repair or replace pressure switch unit is operating or not 2 Check valve may be dirty or 2 Clean gt repair or replace check operating faulty valve Water in air receiver tank 1 Condensation in the air 1 Drain daily or install an receiver automatic drain Oil leaks or appearance 1 Spillage of oil when filling 1 Wipe unit clean of oil on the compressor 2 Overfilling the crankcase 2 Drain oil and fill to proper level 3 Improper grade of oil 3 Replace with proper SAE10W 30 4 Leak at oil filler plug non detergent compressor oil 5 Oil leak at
8. gasket gt cap screw 4 Tighten or replace oil filler plug head gt cylinder or crankcase o and or O ring 6 Loose valve plugs 5 Replace gaskets as required Use pipe dope or gasket 7 Loose side or end plate compound on all cap screw 8 Oil seal leak threads 9 Scratch or burn on the 6 Tighten valve plug crankshaft 7 Tighten plates 8 Replace oil seal 9 File or sand with emery cloth 11 2C03 071 0212
9. gt NEVER TOUCH ANY EXPLOSED METAL PARTS ON COMPRESSOR DURING OR IMMEDIATELY AFTER OPERATION gt TOUCHING THESE AREAS MAY CAUSE SEVER BURNS meh DO NOT REACH AROUND PROTECTIVE SHROUNDS OR ATTEMPT MAINTENANCE UNTIL UNIT HAS BEEN ALLOWED TO COOL 1 5 RISK OF BREATHING DO NOT USE COMPRESSORED AIR FOR BREATHING gt WHEN SPRAING USE RESPIRATORY PROTECTION IN A WELL VENTILED AREA COMPRESSOR AIR FROM THE UNIT MAY CONTAIN POISONOUS VAPOURS WHICH IS NOT SUITABLE FOR INHALEING AND COULD BE HARMFUL TO YOUR HEALTH WORK IN AN AREA WITH GOOD CROSS VENTILATION 1 6 RISK FROM MOVING PARTS UNIT STARTS AUTOMATICALLY DO NOT OPERATE WITH GUARDS OR COVERS REMOVED OR BROKEN ANY REPAIRE REQUIRED ON THE PRODUCT SHOULD BE PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL MOVING PARTS DO NOT TOUCH 1 7 RISK FROM FLYING OBJECTS ALWAYS WEAR ANSI Z87 1 APPROVED SAFETY GLASSES WITH SIDE SHIELDS WHEN USE THE AIR COMPRESSOR ALWAYS WEAR PROPER SAFETY EQUIPMENT WHILE USING COMPRESSORED AIR DONOT DIRECT AIR STREAM TOWARD ANY PARTS OF THE BODY OR AT OTHER PEOPLE UNPLUG POWER CORD AND DRAIN ALL AIR PRESSURE FROM TANK BEFORE SERVICING AND AFTER EACH USE 1 8 RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR ALWAYS PLACED COMPRESSOR ON A PROTECTIVE MAT WHEN TRANSPORTING TO PROTECT AGAINST DAMAGE TO VEHICLE FROM LEAKS NEVER OPERATE COMPRESSOR ON A ROOF OR OTHER ELEVATE
10. lace air filter if necessary 8 2 2 Check oil level and filling up if necessary 8 3 Quarterly or 300 hour checklist 8 3 1 Change compressor oil and filter element 8 3 2 Check safety valve 8 3 3 Check pressure switch unloads to ensure compressor head unloads whenever motor shuts down 8 3 4 Clean and blow off pump fins and motor 8 3 5 Inspect air system for leaks by applying soapy water to all joints Tighten joints if leakages are observed 9 STORAGE WHEN YOU HAVE FINISHED USING THE AIR COMPRESSOR 9 1 Set the on off switch to off and unplug the cordially 9 2 Be sure to drain the water from the air tank 9 3 Protect the electrical cord and air hose from damage 9 4 Store the air compressor in a clean and dry location 10 TROUBLE SHOOTING CONDITION CAUSE CORRECTIVE Compressor do not start 2 Motor overheated Loose electrical connection Check wiring connection Press reset button or wait for automatic reset Low pressure A O N gt Air leak in safety valve Loose tube of fittings Restricted air filter Defective check valve Safety valve manually by pilling upward on ring If condition persists replace valve Tighten fittings 3 Clean or replace 4 Replace safety valve Safety valve releasing on 1 Defect pressure switch or air receiver tank improper adjus
11. r and professional units where the pressure switch would act as a pilot device activating the motor The pressure switch cut in cut out has been preset at the factory gt do not tamper with the settings Never bypass or remove this switch gt as serious damage to equipment or personal injury could result from too high of an air pressure Consult your local distributor or service center should the switch not be operating properly 5 2 3 1 This pressure turn the compressor gt it is operated manually but when it is in the on 5 2 4 5 2 5 position gt it allows the compressor to start up or shut down automatically gt without warning upon air demand Always set this switch to off when the compressor is not in use and before unplugging compressor _ PRESSURE SWITCH ON OFF PRESSURE SWITCH CAVITY W NNA AIR OUTLET FRONT REGULATOR CAVITY SMALL PRESSURE GAUGE AIR PRESSURE REGULATOR The air pressure regulator enables operator to adjust line pressure to the tool in use Never exceed maximum working pressure of the tool gt To adjust gt pull up on knob turn to right to increase pressure gt and to left to decrease pressure GROUNDING INSTRUCTIONS Do not modify the plug that has been provided gt if it does not fit the available outlet the correct outlet should be installed by a qualified electrician The plug must be plugged into an outlet that is properly installed and grounded in accordance
12. self gt Placing materials there will limit the cooling of the air compressor and could lead to premature failure Turn the compressor on Open the air receiver outlet valve and start the unit Ensure air is escaping to atmosphere Allow the unit to operate for a minimum of twenty minutes in this no load condition to lubricate bearings and piston After running the compressor for twenty minutes gt close the valve gt and allow the unit to reach maximum operating pressure Ensure that the compressor shuts down at the preset maximum pressure gt and the head pressure is released through pressure switch Check the air compressor and piping systems for leakages gt and correct as required Shut off of all power to the air compressor before attempting any repair or maintenance gt Stop the compressor gt and check the oil level in the crankcase Add oil as required Your compressor is ready for use Before doing any maintenance or adjustments to your air compressor the following safety precautions should be taken A DISCONNECT ELECTRICAL POWER B DRAIN AIR RECEIVER OF AIR PRESSURE 8 MAINTENANCE CHECK LIST 8 1 Daily checklist 8 1 1 Check oil level 8 1 2 Drain condensation from air receiver tank 8 1 3 Check for any unusual noise or vibration 8 1 4 Be sure all nuts and bolts are tight 8 2 Weekly checklist 8 2 1 Clean air filter by opening air filter cap Rep
13. tment 2 Defective safety valve Check for proper adjustment and if problem persists replace pressure switch Replace safety valve Oil discharge and 1 Improper oil viscosity excessive carbon formation or appearance 2 Overfilling the crankcase Replace oil with SAE10W 30 non detergent compressor oil of water and oil in the air with oil 2 Drain oil and fill to proper level lines 3 Restricted air intake filter 3 Clean or replace filter 4 Carbon exhaust valves 4 Clean or replace 5 Worn valves 5 Replace valve assembly 6 Worn piston rings 6 Replace piston ring 7 High ambient temperature 7 Install a moisture separator and or and or humidity dryer follow by and oil filter 8 High percentage of running 8 Check for air leakage If no leaks time are found you may required an additional compressor unit as your air demand is too much for existing unit Excessive noise 1 Loose valve 1 Inspect valve for damage replace 3 Piping loose crankcase piston 7 Worn bearings 2 Noisy only during start up gt Check for loose belts 4 Unit not installed level 5 Improper grade of oil in 6 Carbon or foreign material on a A O N as required Adjust for proper tension Tighten as required Ensure that unit is mounted level Replace oil with SAE10W 30 non detergent
14. ut by a competent electrician and installed a way which meets all applicable codes and regulations Failure to connect the air compressor correctly to your buildings electrical services may result in serious personal injury or damage to the equipment Please note that under normal conditions the air compressor will operate intermittently Should it be necessary to service that air compressor ensure the power source has been shut down This must be down to prevent personal injury or damage to the unit If the supply cord is damaged it must be replaced by the manufacturer or its service agent or a suitable qualified person in order to avoid a hazard 5 2 1 MOTOR Wiring must be down in a manner that full voltage nameplate 10 is available at the motor terminals during startup Use of an incorrect electrical motor for your particular building service will result in premature motor failure and is not covered by PUMA compressor or motor manufacture s warranty 5 2 2 RESET SWITCH Ensure that all guards and shrouds are in place before pressing reset switch to restart the motor If the motor shuts down because of overload gt wait 10 15 minutes so the motor can cool down gt then press the reset switch to restart motor gt The reset switch button is located on the motor housing The pressure switch located on the compressor unit acts as a pilot device activating the coil on the magnetic starter except on contracto
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