HULK POWER HP02P005S1 Use and Care Manual
Contents
1. 2 0 HP Amperage ita has Eaa RAN A NAAR Xa AEE AEAEE EE aa pea Ei Eiaa 11 5A RPM no load SE eL etm 1 720 Phase cent E eee enh ec ee ee 1 cect 60Hz Operating to D UE 125 PSI BET i o 2 5 x 2 5 Gallon WARNING ALL ELECTRICAL INSTALLATIONS MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY ALL ADJUSTMENTS OR REPAIRS MUST BE PERFORMED WITH THE COMPRESSOR DISCONNECTED FROM THE POWER SOURCE FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY POWER SUPPLY WARNING YOUR COMPRESSOR MUST BE CONNECTED TO A 110V WITH A MINIMUM 15 AMP BRANCH CIRCUIT FAILURE TO CONNECT IN THIS WAY CAN RESULT IN INJURY FROM SHOCK OR FIRE GROUNDING Your compressor must be properly grounded Not all outlets are properly grounded If you are not sure if your outlet is properly grounded have it checked by a qualified electrician WARNING IF NOT PROPERLY GROUNDED THIS COMPRESSOR CAN CAUSE ELECTRICAL SHOCK PARTICULARLY WHEN USED IN DAMP LOCATIONS TO AVOID SHOCK OR FIRE IF THE POWER CORD IS WORN OR DAMAGED IN ANY WAY HAVE IT REPLACED IMMEDI ATELY If this compressor should malfunction or breakdown grounding provides a path of least resistance for electric current to reduce the risk of electric shoc2. 2 0 HP AIR COMPRESSOR c P ctl E e INSTRUCTION MANUAL Heavy duty rubber feet for rough terrain on job sites Breathable Air Warning This compressor pump is NOT equipped and should NOT be used as is to supply breathing quality air For any application of air for human consumption you must fit the air compressor pump with suitable in line safety and alarm equipment This additional equipment is necessary to properly filter and purify the air to meet minimal specifications for Grade D breathing as described in Compressed Gas Association Commodity Specification G 7 1 1966 OSHA 29 CFR 1910 134 and or Canadian Standards Associations CSA DISCLAIMER OF WARRANTIES In the event the compressor is used for the purpose of breathing air application and proper in line safety and alarm equipment is not simultaneously used existing warranties are void and Hulk air force technology amp AIRBASE Industries LLC disclaims any liability whatsoever for any loss personal injury or damage CALIFORNIA PROPOSITION 65 A This product or its power cord may contain chemicals known to the state of California to cause cancer and birth defects or other reproductive harm Wash hands after handling READ INSTRUCTION MANUAL BEFORE OPERATING RISK OF FIRE OR EXPLOSION DO NOT SPRAY COMBUSTIBLE FLAMMABLE LIQUID IN A CONFINED AREA SPRAY AREA MUST BE WELL VENTILATED DO NOT SMOKE WHILE SPRAYI
3. NO 10 0 25 FEET 26 50 FEET 51 100 FEET FIGURE 2 OPERATION CONTROLS j 1 AIR COMPRESSOR PUMP To compress air the piston moves up and down in the cylinder On the downstroke air is drawn in through the intake valves The exhaust valves remain closed On the upstroke of the piston air is compressed The intake valves close and compressed air is forced out through the exhaust valves CHECK VALVE A FIG 3 When the air compressor is operating the check valve is open allowing compressed air to enter the air tank When the air compressor reaches Cut Out pressure the check valve closes allowing air pressure to remain inside the air tank ON AUTO OFF SWITCH A FIG 5 Turn this switch ON by lowering lever downwards to provide power to the automatic pressure switch and lift to turn compressor OFF PRESSURE SWITCH B FIG 5 The pressure switch automatically starts the motor when the tank pressure drops below the factory set Cut In pressure It also stops the motor when the air tank pressure reaches the factory set Cut Out pressure REGULATOR B FIG 6 The air pressure coming from the air tank is controlled by the regulator Turn the regulator knob clockwise to increase pressure and counterclockwise to decrease pressure To avoid minor readjustment after making a change in the pressure setting always approach the desired pressure from a lower pressure When reducing from a higher to a lower
4. Unattended operation of this compressor could result in personal injury or property damage RISK OF BURSTING WHAT CAN HAPPEN 1 Failure to properly drain condensed water from the tank causing rust and thinning of the steel tank 2 Modifications or attempted repairs to the tank 3 Unauthorized modifications to the unloader valve safety valve or any other components which control tank pressure 4 Excessive vibration can weaken the air tank and cause rupture or explosion 5 Attachments amp Accessories Exceeding the operating pressure of air tools can cause them to explode RISK OF BURNS WHAT CAN HAPPEN Touching exposed metal such as the compressor head or outlet tubes can result in serious burns RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR WHAT CAN HAPPEN Oil can leak or spill and could result in fire or breathing hazard serious injury or death can result Oil leaks will damage carpet paint or other surfaces in vehicules or trailers HOW TO PREVENT Always operate the compressor in a well ventilated area free of combustible materials gasoline or solvent vapors If spraying flammable materials locate the compressor at least 20 feet away from the spray area An additional length of hose may be required Store flammable materials in a secure location away from the compressor Never place objects against or on top of the compressor Operate compressor in an open area at least 12 inches away f
5. your air compressor are necessary to maintain proper operating temperature Do not place rags or other containers on or near these openings ADDITIONAL REGULATORS AND CONTROLS Since the air tank pressure is usually greater than that which is needed a regulator is employed to control the air pressure ahead of any individual driven device Separate air transformers which combine the function of air regulation moisture and dirt removal should be used where applicable BREAK IN PROCEDURES NOTE SERIOUS DAMAGE MAY RESULT IF THE FOLLOWING BREAK IN INSTRUCTIONS ARE NOT CLOSELY FOLLOWED THIS PROCEDURE IS REQUIRED BEFORE THE AIR COMPRESSOR CAN BE PUT INTO SERVICE AFTER REPLACING THE CHECK VALVE AND WHEN THE PISTON OR THE CYLINDER SLEEVE IS REPLACED A Fill crankcase with oil as described in Changing Oil in the maintenance section on the following page B Set the pressure switch lever to the OFF position C Plug the power cord into the correct 110V branch circuit receptacle D Fully open the drain valve A Fig 4 by turning it counterclockwise to prevent air pressure build up in the tank E Move the pressure switch lever to ON AUTO The compressor will start F Run the compressor for 15 minutes Make sure the drain valve is open and there is no tank pressure build up by watching the tank pressure gauge G After 15 minutes close the drain valve by turning clockwise The air receiver will fill to Cut Out pressure a
6. 203003 CY00602001 P140302000 RR30503120 Co L CR00802001 SW30502080 CC00502001 FB51200006 OR30603000 OB40602000 CR00202000 OS30602001 BB30701003 AR10103200 BB30701001 FC10103201 WW30505000 Wave washer FA40702000 SR30504140 Shaft retaining ring CA40801070 MC50102000 L Co Oo OQ o G O C1 O1 O1 O1 O1 C A N O N N co lt 1000 Cass Drive Clayton Ohio 45315 Toll Free 866 294 4153 Fax 937 540 1157 sales emaxcompressor com
7. BLE POSSIBLE CAUSE CORRECTIVE ACTION No start condition Fuse blown or circuit breaker tripped Check voltage or eliminate extension cord or reset Loose electrical connections Check wiring connections Overheated motor Press the reset button or wait for automatic reset Low pressure Air leak in safety valve Check valve manually by pulling upwards on ring If condition persists replace valve Restricted air filter Clean or replace as necessary Defective check valve Replace check valve Safety valve releasing Defective pressure switch or improper Check for proper adjustment if problem persists replace adjustment pressure switch Oil discharge in air Improper oil viscosity Replace oil with SAE 10W30 or SAE 10W20 non detergent Too much oil in crankcase compressor oil Drain crankcase and fill to proper level Compressor overheated Air pressure regulated too high Restricted air filter Replace filter PARTS DIAGRAM MODEL HP02P005S1 PARTS LIST MODEL 2 00551 ME C 28 NN CS30106090 SW30502060 CH00102001 AF50901020 VA40201000 VG40502020 50 1 CN50705000 2 UN51200001 PC50601000 RH51002003 F20203000 530315011 Pan head screw 530316001 WA30501051 SW30502051 Spring washer HN30405001 MA50401010 5 EL50703001 _68 TP50701006 Threaded pug 4 69 51301000 Hose 1 6 PR50802311 EP50802301 CW51200000 Copper washer EL40101010 OP41001040 Overload protector reset RC20
8. ER WILL CORRODE AND WEAKEN THE AIR TANK CAUSING A RISK OF AIR TANK RUPTURE NOTE If drain valve is plugged pull ring on safety valve B Fig 4 and hold until air pressure has been released The valve can then be removed cleaned and reinstalled 11 After the water has been completely drained turn drain valve to close The air compressor can now be stored MAINTENANCE amp STORAGE MAINTENANCE the cord plug are making good contact in the outlet Also check for Before doing any maintenance or adjustments to your air compressor blown fuses or open circuit breakers in the line the following safety precautions should be taken Disconnect electrical power STORAGE Drain air tank of pressure 1 Set the ON AUTO OFF lever to OFF 2 Turn the regulator counterclockwise to set the outlet pressure to Daily or before each use zero 1 Check oil level The oil level should be centered with the red dot 3 Remove the air tool or accessory which appears in the oil sight glass C Fig 8 4 Pull ring on safety valve B Fig 4 allowing air to bleed from the tank 2 Drain condensation from tank until tank pressure is approximately 20psi Release safety valve ring 3 Check for any unusual noise or vibration 5 Drain water from air tank Turn drain valve A Fig 4 counterclock 4 Be sure all nuts and bolts are tight wise to open NOTE If drain valve is plugged pull ring on safety valve B Fig 4 and Monthly hold until ai
9. NG OR SPRAY WHERE SPARK OR FLAME IS PRESENT ARCING PARTS KEEP COMPRESSOR AT LEAST 20 FEET AWAY FROM SPRAYING AREA AND ALL EXPLOSIVE VAPORS RISK OF INJURY DO NOT DIRECT AIR STREAM AT BODY USE EYE PROTECTION COMPRESSOR STARTS AUTOMATICALLY MOVING PARTS DO NOT TOUCH KEEP GUARDS IN PLACE COMPRESSOR DOES NOT SUPPLY BREATHABLE AIR RISK OF BURSTING DO NOT ADJUST REGULATOR TO RESULT IN OUTPUT PRESSURE GREATER THAN MARKED MAXIMUM PRESSURE OF ATTACHMENT IF A REGULATOR HAS NOT BEEN INSTALLED USE ONLY ATTACHMENT RATED AT 200 PSI ORHIGHER DO NOT WELD ON OR REPAIR TANK REPLACE DO NOT OPERATE WITHOUT PROPER ASME SAFETY VALVE IN PLACE RISK OF ELECTRICAL SHOCK HAZARDOUS VOLTAGE DISCONNECT FROM POWER SOURCE BEFORE SERVICING COMPRESSOR MUST BE GROUNDED DO NOT USE GROUNDING ADAPTORS DO NOT EXPOSE TO RAIN STORE INDOORS IF CONNECTED TO A CIRCUIT PROTECTED BY FUSES USE TIME DELAY FUSE MARKED D COMPLIES WITH CCR462 L 2 DO NOT USE BELOW GARAGE FLOOR OR GRADE LEVEL DRAIN TANK EVERYDAY TO PREVENT CORROSIONAND POSSIBLE INJURY DUE TO TANK DAMAGE IMPORTANT INFORMATION HULK 2 Year limited warranty on pumps LIMITED WARRANTY 1 Year limited warranty on parts amp labor FOR THIS 2 0 HP AIR COMPRESSOR PROOF OF PURCHASE Please keep your dated proof of purchase for warranty and servicing purposes REPLACEMENT PARTS Replacement parts for this tool are available at our authorized HULK servic
10. e centers across USA For servicing contact or return to the retailer where you purchased your product along with your proof of purchase Please use the 10 digit part numbers listed in this manual for all part orders where applicable LIMITED TOOL WARRANTY HULK makes every effort to ensure that this product meets high quality and durability standards HULK warrants to the original retail consumer a 2 year limited warranty as of the date the product was purchased at retail and that each product is free from defects in materials Warranty does not apply to defects due directly or indirectly to misuse abuse negligence or accidents repairs or alterations and lack of maintenance HULK shall not be liable for death injuries to persons or property or for incidental special or consequential damages arising from the use of our products To take advantage of this warranty the manufacturer part must be returned for examination by the retailer Shipping and handling charges may apply If a defect is found HULK will either repair or replace the product IMPORTANT SAFETY INSTRUCTIONS RISK OF EXPLOSION OR FIRE WHAT CAN HAPPEN It is normal for electrical contacts within the motor and pressure switch to spark If electrical sparks from the compressor come in contact with flammable vapors they may ignite causing fire or explosion Restricting any of the compressor ventilation openings will cause serious overheating and could cause a fire
11. he pressure release valve allows the motor to restart freely When the motor stops running air will be heard escaping from this valve for a few seconds No air should be heard leaking when the motor is running or continuous leaking after unit reaches Cut Out pressure SAFETY VALVE B FIG 4 If the pressure switch does not shut off the air compressor at its Cut Out pressure setting the safety valve will protect against high pressure by popping out at it s factory set pressure slightly higher than the pressure switch Cut Out setting WARNINGI If the safety valve does not work properly over pressurization may occur causing air tank rupture or an explosion Pull the ring daily on the safety valve to make sure that the safety valve eoe operates freely If the valve is stuck or does not operate smoothly it must be replaced with the same x 7 type of valve before operating again j FA a A i FIGURE 7 BREAK IN PROCEDURES amp OPERATION A LOCATION OF THE AIR COMPRESSOR Your compressor comes almost completely assembled Only the air filter needs to be installed Operate the air compressor in a dry clean cool well ventilated area The air compressor pump and case are designed to allow for proper cooling Clean or blow off dust or dirt that collects on the air compressor A clean air compressor runs cooler and provides longer service The ventilation openings on
12. k This compressor is equipped with a cord having an grounding conductor and grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances WARNING TO MAINTAIN PROPER GROUNDING DO NOT REMOVE OR ALTER THE GROUNDING PRONG IN ANY MANNER 110V OPERATION As received from the factory your compressor is ready to run for 110V operation This machine is intended for use on a circuit that has an outlet and a plug which looks like the one illustrated in Fig 1 WARNING DO NOT USE A TWO PRONG ADAPTOR FOR THEY ARE NOT IN ACCORDANCE WITH LOCAL CODES AND ORDINANCES NEVER USE IN USA EXTENSION CORDS The use of any extension cord will cause some loss of power IT IS RECOMMENDED TO USE ALONGER AIR HOSE INSTEAD OF AN EXTENSION CORD If you do not have a choice use the table in Fig 2 to determine the minimum wire size A W G American Wire Gauge extension cord Use only 3 wire extension cords which have 3 prong grounding type plugs and 3 hole receptacles which accept the tool s plug For circuits that are further away from the electrical circuit box the wire size must be increased proportionately in order to deliver ample voltage to the compressor motor Refer to Fig 2 for wire length and size PROPERLY GROUNDED OUTLET CURRENT CARRYING PRONGS FIGURE 1 LENGTH OF CONDUCTOR WIRE SIZES REQUIRED AMERICAN WIRE GAUGE 110V LINES NO 12 NO 12
13. nd the motor will stop The compressor is now ready for use OPERATING PROCEDURES Preparation for use 1 Before attaching an air hose or accessories make sure the OFF AUTO lever is set to OFF and the air regulator is closed Once this is done you can now attach a hose or an accessory WARNING Too much air pressure causes a hazardous risk of bursting Check the manufacturer s maximum pressure rating for air tools and accessories The regulator outlet pressure must never exceed the maximum pressure rating of the tool being used Turn the ON AUTO OFF lever to ON AUTO and allow tank pressure to build Motor will stop when tank pressure reaches Cut Out pressure 4 Open the regulator by turning it clockwise Adjust the regulator to the correct pressure setting The compressor is ready for use 5 Always operate the air compressor in well ventilated areas free of gasoline or other solvent vapors Do not operate the compressor near the spray area After Use 6 Set the ON AUTO OFF lever to OFF 7 Turn the regulator counterclockwise to set the outlet pressure to zero 8 Disconnect the air tool or accessory 9 Pull ring on safety valve B Fig 4 allowing air to bleed from the tank until tank pressure is approximately 20 psi Release safety valve ring 10 Drain water from air tank Turn drain valve A Fig 4 counterclockwise to open WARNING WATER WILL CONDENSE IN THE AIR TANK IF NOT DRAINED REGULARLY WAT
14. r pressure has been released The valve can then be 1 Inspect air system for leaks by applying soapy water to all joints removed cleaned and reinstalled Tighten those joints if leakage is observed 6 After the water has been completely drained turn drain valve to 250 hours or six months whichever comes first close The air compressor can now be stored 1 Change compressor oil See following instructions 7 Store the air compressor in a clean and dry location 2 Replace oil more often if compressor is used near paint spraying operations or in dusty environments CHANGING OIL To change oil oil must be drained from the crank case by unscrewing and removing oil sight glass C Fig 8 Drain oil and replace oil sight glass To fill the crank case with oil first unscrew and remove oil breather cap A pour air compressor oil SAE 10W30 or SAE 10W20 weight non detergent compressor oil into crank case oil opening B until the oil level reaches the red dot at the center mark of the oil sight glass Secure oil breather cap A KEEP TOOL CLEAN Periodically blow out all air passages with dry compressed air Clean all plastic parts with a soft damp cloth NEVER use solvents to clean plastic parts They could possibly dissolve or otherwise damage the material CAUTION Wear safety glasses while using compressed air FAILURE TO START FIGURE 7 Should your compressor fail to start check to make sure the prongs on TROUBLE SHOOTING TROU
15. rom any wall or obstruction that would restrict the flow or fresh air to the ventilation openings Operate compressor in a clean dry and well ventilated area Do not operate compressor indoors in a confined area Always remain in attendance with the compressor when it is operating HOW TO PREVENT Drain tank daily or after every use If the tank develops a leak replace tank or get a new air compressor Never drill into weld or make any modifications to the tank or its attachments The tank is designed to withstand specific operating pressures Never make adjustments or parts substitutions to alter the factory set operating pressures For essential control of air pressure you must install a pressure regulator and pressure gauge to the air outlet HOW TO PREVENT Never touch any exposed metal parts on compressor during or immediately after operation The compressor will remain hot several minutes after use Do not reach around protective shrouds or attempt maintenance until the compressor has cooled down completely HOW TO PREVENT Always place compressor on a protective mat when transporting to protect against damage to vehicle from leaks Remove compressor from vehicles immediately apon arrival MM P SPECIFICATIONS amp ELECTRICAL INFORMATION SPECIFICATIONS TD ete 02 00551 eR T 110V Horsepower de
16. setting first reduce the pressure less than that desired then bring it up to the desired pressure Depending on the air requirements of each particular accessory the outlet regulated air pressure may have to be adjusted while operating the accessory A OUTLET PRESSURE GAUGE C FIG 6 The outlet pressure gauge indicates the air pressure FIGURE 4 available at the outlet side of the regulator The pressure is controlled by the regulator and is always less than or equal to the tank pressure TANK PRESSURE GAUGE A FIG 6 The tank pressure gauge indicates the reserve air pressure in the tank COOLING SYSTEM This compressor contains an advanced design cooling system The cooling system works when air is being expelled DRAIN VALVE A FIG 4 The drain valve is located at the base of the air tank and is used to drain condensation from the tank to prevent corrosion Drain tank after each use MOTOR THERMAL OVERLOAD PROTECTOR RESET A FIG 7 The electric motor has an automatic thermal overload protector If the motor overheats for any reason the thermal overload protector will shut off the motor The motor must be allowed to cool before restarting Press the reset button A PRESSURE RELEASE VALVE The pressure release valve located on the side of the pressure switch is designed to automatically release compressed air from the compressor head and the outlet tube when the air compressor reaches Cut Out pressure or is shut off T
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