AC30A COMPRESSOR OWNERS MANUAL - Auto Cranecompressor when the compressor is running only. This is a...

AC30ACOMPRESSOR

OWNERS MANUALRev. 03/15/2011

Serial No. __________________Mailing Address:P.O. Box 580697Tulsa, OK 74158-0697

Physical Address:4707 N. Mingo Rd.Tulsa, OK 74117-5904 Phone (918) 836-0463Manual No. AC30A Fax (918) 834-5979Rev. 07/08/2008 http://www.autocrane.com

To: Fax:

From: Date:

Re: Pages:

Name: Phone:

Address:

City: State: Zip:

Contact:

Name:

Address:

City: State: Zip:

Contact:

VIN #

ONE REGISTRATION FORM PER UNIT (CRANE OR BODY)Registration form must be mailed or faxed within 15 days of customer installation.

Mail to:

Warranty Department

Auto Crane Company

P.O. Box 581510

Tulsa, OK 74158-0697

Date Product Delivered: Date Processed:*

* For Auto Crane use only

Product Information: (Required for Warranty Activation)

Model No.: Serial No.:

E-mail Address:

Distributor Information: (Required for Warranty Activation)

Product Registration

E-mail Address:

(Required for Warranty Activation)

Auto Crane Warranty Registration

(918) 834-5979Warranty Department

End User Information:

Fax Transmission

Warranty Registration Rev. 050905

10/09

Rev Date Section(s)OrPage(s) Description of Change09/02/03 Last page New 2-year warranty policy to replace 1-year warranty

policy05/09/05 2nd Quarter New Revisions11/28/05 3-1.0.0 Updated for new hydraulic motor06/10/06 Updated for new machine design.07/12/07 Bill of Materials Audit08/13/07 Updated Drawing11/28/11 Updated Drawing 200280-999

AC30A

OWNER’S MANUAL – REVISION RECORD

10/09

WARNINGS

READ THIS PAGE

WARNING! Federal law (49 cfr part 571) requires that the Final Stage Manufacturer of a vehicle certify that the vehicle complies with all applicable federal regulations. Any modifications performed on the vehicle prior to the final state are also considered intermediate stage manufacturing and must be certified as to compliance. The installer of this crane and body is considered on of the manufacturers of the vehicle. As such a manufacturer, the installer is responsible for compliance with all applicable federal and state regulations, and is required to certify that the vehicle is in compliance.

WARNING! It is the further responsibility of the installer to comply with the OSHA Truck Crane Stability Requirements as specified by 29 CFR part 1910.180 (C) (1).

WARNING! NEVER OPERATE THE CRANE NEAR ELECTRICAL POWER LINES! Death or serious injury will result from boom, line, or load contacting electric lines. Do not use crane within 10 feet (3.05m) of electric power lines carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. SEE DANGER DECAL (P/N 040529) in this Owner's Manual.

WARNING! NEVER.........................................

EXCEED load chart capacities (centerline of rotation to hoist hook).

Un-reel last 5 wraps of cable from drum!

Wrap cable around load!

Attempt to lift or drag a load from the side! The boom can fail far below its rated capacity.

Weld, modify, or use unauthorized components on any Auto Crane unit! This will void any warranty or liability. Also failure of the crane may result.

Place a chain link on the tip of the hook and try to lift a load!

Use a sling bar or anything larger than the hook throat that could prevent the hook latch from closing, thus negating the safety feature!

Hold on any pendant Select Switch that will cause unsafe operating conditions!

WARNING! In using a hook with latch, ALWAYS make sure that the hook throat is closed before lifting a load! Proper attention and common sense applied to the use of the hoist hook and various slings will prevent possible damage to material being hoisted and may prevent injury to personnel.

WARNING! Failure to correctly plumb and wire crane can cause inadvertent operation and damage to crane and/or personnel!

WARNING! Auto Crane Company remote controlled cranes are not designed or intended to be used for any applications involving the lifting or moving of personnel.

WARNING! ALWAYS operate the crane in compliance with the load capacity chart. DO NOT USE the overload shutdown device to determine maximum rated loads, if the crane is equipped with this type of device.

10/09

SPECIFICATIONS.............................................................................. 1-1.0.0

GENERAL DIMENSIONS................................................................... 1-2.0.0

INSTALLATION INSTRUCTIONS....................................................... 1-3.0.0

OPERATION....................................................................................... 1-4.0.0

SPARE PARTS LIST........................................................................... 1-6.0.0

HYDRAULIC INSTALLATION............................................................. 2-1.0.0

PNEUMATIC SCHEMATIC................................................................. 2-2.0.0

ELECTICAL SYSTEM......................................................................... 2-3.0.0

HYDRAULIC SCHEMATIC.................................................................. 2-4.0.0

GENERAL ASSEMBLY........................................................................ 3-1.0.0

MAINTENANCE.................................................................................. 4-1.0.0

TROUBLESHOOTING......................................................................... 4-2.0.0

RECEIVER TANK................................................................................ 5-1.0.0

FILTER/REGULATOR/LUBRICATOR..................................................6-1.1.0

MISC....................................................................................................7-1.0.0

WARRANTY............................................................................................ LAST PAGE

AC30A HYDRAULIC AIR COMPRESSOROWNER’S MANUAL

TABLE OF CONTENTS

10/09

Dimensions

Width: 25.0 in. (AT TOP)20.0 in. (AT BASE)

Height: 24.5 in.Length: 28.25 in.Weight: 250 lbs. w/cage

Performance Data

28.8* cfm (Free Air Cubic Feet per Minute) @100 psig air outlet pressure and 1800rpm.

Piston Displacement: 48.5 cfm

*Reference Conditions:Absolute Inlet Pressure: 14.5 psiRelative Air Humidity:0 %Air Inlet Temperature:68° F.

Hydraulic Requirements

Flow (Max): 12 gpm (45.4 l/min)Pressure: 2500 psi (172 bar)Fluid Type: Anti-Wear HydraulicFluid viscosity: 150 SSU @ 100°F

Electrical System Requirements

Voltage: 12 Volts DCCurrent: 2.5 Amps

Rotation

Bi-rotational Radial Fan Blade

Hose Connections

Pressure: -12 JIC MALEReturn: -12 JIC MALE

Technical Data

Maximum Air Pressure: 145 psigNominal RPM: 1800 rpmCrankcase Oil Capacity: 1.5 qtsApprox. Oil Consumption: .025 oz/hrMaximum Temperature (@ Outlet): 165°FNoise Level: 84 dB(A)

1-1.0.0

GENERAL SPECIFICATIONSAC30A HYD AIR COMPRESSOR

10/091-2.0.0

20.00

24.11

24.38

28.00

29.01

GENERAL DIMENSIONS AC30A

10/09

1 Locate air pump in a well ventilatedarea on truck body.

2 Secure to truck body throughbottom side rails using four(4) 3/8- 24 NF x 2¾ Grade 5 bolts.Four (4) new 7/16 diameter holesmay be made in the side frame railto allow for obstruction problems.

3 Remove plastic cap from “T” port inthe hydraulic valve block and installreturn line to cooler or reservoir.

4 Remove plastic cap from “P” portin the hydraulic valve block andinstall pressure line from hydraulicpump.

5 The mating electrical connector has4 wires. Red, black and orange. Runred power wire to a 10 amp fusedswitched ignition source. The blackto a frame ground source. Theorange wire is optional and is apower feed source from thecompressor when the compressor isrunning only. This is a 10 amp max.power feed.

6 Attach air hose to the straight 5/8"fitting (37 degree JIC male) on thecompressor discharge line.

7 Follow initial start-up procedure.

1-3.0.0

AC30AINSTALLATION INSTRUCTIONS

10/09

BASIC OPERATION

Air is drawn through the intake filter,intake manifold and suction discs intothe cylinders. The air is compressed,then discharged through the deliverydiscs to the temperature reducer, wherethe heat of the compressed air is partlyremoved. From the temperature reducerthe compressed air is dischargedthrough the 5/8” JIC customerconnection points.

AUTO RUN MODE

When the demand for air is moderate, theunit should be run in the auto mode.This allows the compressor to produceair until the pressure reaches the upperlimit of the pressure switch and stop. Atthis point it shuts the compressor off.When the tank pressure reduces to thelower limit of the pressure switch theunit will start up and continue producingair.

CAUTION: When the hydraulic systemshuts down a shock wave is delivered tothe return line. Locate the hydrauliccoolers and filters a minimum of 10’away.

The pressure switch is preset tospecified settings.

Pressure Switch:Shutoff: 150 psigRestart: 110 psig

1-4.0.0

OPERATION — AC30A

10/09

1 Read the AC30A Owner’s Manual.

2 Check all wiring for looseconnections.

3 Check oil level in sight gauge. Itshould be filled to the middle of thesight glass. If not, fill to the properlevel. Fill with PAO syntheticlubricant equivalent to Chevron-GulfGSL 838A or Summit SH-46. Ifpetroleum based crankcase oil isrequired by operator, use an SAE10W oil, API classification CD of SF,Mil Spec MIL-L-2104C or MIL-L-46152.

CAUTION: Do not mix oil types.

4 Check that pressure switch operatesat the pressure limits specified.

5 Check the oil fill cap on top ofcompressor (yellow knob) fortightness.

6 Check hydraulic fluid flow.

CAUTION: More than 12 GPM willbuild excess heat in the system.

7 Check all piping for leaks.

1-5.0.0

AC30AINITIAL START-UP PROCEDURE

10/091-6.0.0

ITEM QTY PART NO. DESCRIPTION

1 3 750107000 AIR FILTER2 5 750097000 OIL, CRANKCASE (QT BOTTLES OF PAO OIL)3 1 302688-012 COIL, HYD VALVE SOLENOID/RELIEF

AC30A RECOMMENDEDSINGLE UNIT SPARE PARTS LIST

10/092-1.0.0

TYPICAL AC30A / CRANEHYDRAULIC INSTALLATION

10/092-2.0.0

PNEUMATIC SYSTEM SCHEMATIC

10/092-3.0.0

AC30A ELECTRICAL SYSTEMP/N: 200220-999

10/092-4.0.0

AIR/HYDRAULIC/ELECTRICALSCHEMATIC P/N: 701106

10/093-1.0.0

AC30A COMPR & PARTS SYS.P/N: 200281-999

1 1

2 2

3 3

4 4

5 5

6 6

7 7

8 8

AA

BB

CC

DD

Pa

rts

List

DE

SC

RIP

TIO

NP

AR

T N

UM

BE

RQ

TY

ITE

M

ELB

OW

, HY

D 1

/2 M

JIC

X -

10 M

SA

E97

0408

-088

11

MO

TO

R, H

YD

1.2

9 A

3/4

-RD

SP

CC

W H

P30

5258

1

2W

AS

HE

R, F

LAT

GR

8 3/

893

8206

-071

83

NU

T, N

YLO

C G

R8

3/8-

1692

5506

-198

44

HU

B, D

RIV

E C

OU

PLI

NG

R38

(.75

0 D

IA B

OR

E).

0005

3012

66

15

SP

IDE

R, D

RIV

E C

OU

PLI

NG

R38

3012

671

6W

AS

HE

R, L

OC

8M

M93

8808

-200

47

BO

LT, H

EX

GR

10.9

8M

M X

30M

M92

9208

-300

48

CO

MP

R, 3

5 P

IST

ON

AC

3047

601

9A

DA

PT

ER

, 1/2

BS

PP

X 1

/2 N

PT

3026

31

110

BO

LT, H

EX

GR

8 3/

8-16

X 3

9298

06-3

004

11A

DA

PT

ER

, HY

D M

TD

TO

AC

30 C

OM

PR

3057

671

12W

AS

HE

R, L

OC

GR

8 3/

893

7806

-094

213

BO

LT, H

EX

GR

8 3/

8-16

X 1

1/4

9298

06-1

252

14A

DA

PT

ER

, 3/8

MB

SP

T X

3/8

FN

PT

9892

06-0

381

15H

OS

E, .

500

OIL

DR

AIN

AC

3030

2636

1.

167

FT

16H

UB

, DR

IVE

CO

UP

LIN

G 3

5MM

X10

X8M

M K

EY

3054

34

117

CLA

MP

, HO

SE

3/4

WO

RM

GE

AR

3000

33-0

752

18C

AP

, PIP

E H

EX

1/2

ZIN

C90

6030

-020

119

ELB

OW

, HY

D 3

/4 M

JIC

X -

12 M

SA

E97

0412

-106

120

CO

NN

EC

TO

R, 1

/2 B

AR

B X

1/2

MN

PT

9748

08-0

501

21S

EA

L, W

AS

HE

R 1

/2 M

BS

PP

3085

251

22

SH

EE

T

2002

811

1 O

F

RE

V 2

CO

MP

R &

PA

RT

S, A

C30

AU

TO

CR

AN

EP

.O. B

OX

580

697

TU

LSA

, OK

741

58-0

697

N/A

PA

TH

MA

TE

RIA

L

G:\I

nven

tor

File

s\20

0k\2

0028

1.dw

g

1/11

/200

6N

DD

DR

AW

N

CH

EC

KE

D

1=2

D

DE

SC

RIP

TIO

N

DW

G N

OS

CA

LES

IZE

UN

MA

CH

INE

D S

UR

FA

CE

S

FR

AC

TIO

NA

L `

1/1

6

DE

CIM

AL

.03

AN

GU

LAR

` 1

°

DO

NO

T S

CA

LE

TOL

ER

AN

CE

SU

NL

ES

S N

OT

ED

MA

CH

INE

D S

UR

FA

CE

S

NO

MIN

AL

DIM

.

0.00

0 T

O 1

.000

.

010

1.00

1 T

O 5

.000

.

015

5.00

1 T

O 1

0.00

0 `

.020

10.0

01 &

OV

ER

`.0

25

TH

IS D

RA

WIN

G A

ND

ALL

IN

FO

RM

AT

ION

TH

ER

EIN

IS

TH

E P

RO

PE

RT

Y O

F

AU

TO

CR

AN

E, I

S

CO

NF

IDE

NT

IAL

AN

D M

US

T

NO

T B

EM

AD

E P

UB

LIC

OR

C

OP

IED

. IT

IS L

OA

NE

D

SU

BJE

CT

TO

RE

TU

RN

UP

ON

D

EM

AN

D, I

S N

OT

TO

BE

US

ED

D

IRE

CT

LY O

R IN

DIR

EC

TLY

IN

AN

YW

AY

DE

TR

IME

NT

IAL

TO

T

HE

INT

ER

ES

T O

F A

UT

O

CR

AN

E.

PR

OP

RIE

TA

RY

IN

FO

RM

AT

ION

2A

DD

ED

308

525

3/11

/201

1M

CM

1R

EP

LAC

ED

(2)

929

806-

100

WIT

H 9

2980

6-12

57/

7/20

08M

CM

RE

VIS

ION

HIS

TO

RY

RE

VD

ES

CR

IPT

ION

DA

TE

EN

G

9

4

3

3

11

18

16

18

192

1

1413

8

7

12

5

6

17

122

10

15 21

2

10/093-2.0.0

AC30A DISCHARGE & PARTS SYS.P/N: 200283-999

Pa

rts L

ist

ITE

MQ

TY

PA

RT

NU

MB

ER

DE

SC

RIP

TIO

N1

19

62

010

-05

0

BU

LK

HE

AD

, 5

/8 J

IC X

1/2

FN

PT

21

975

104

-01

2

EL

BO

W, C

OM

PR

SN

1/4

TU

BE

X 1

/8 M

NP

T

33.0

83

FT

302

636

H

OS

E,

.500

OIL

DR

AIN

GR

AY

2

42

970

308

-05

0

EL

BO

W, H

YD

.5

00 B

AR

B X

.5

00 M

NP

T

51

964

808

-05

0T

EE

, P

IPE

1/2

F X

1/2

M X

1/2

F6

43

00

033

-07

5C

LA

MP

, H

OS

E 3

/4 W

OR

M G

EA

R

74

929

104

-10

0B

OLT

, H

EX

GR

5 1

/4-2

0 X

1

84

938

604

-07

1W

AS

HE

R,

FLA

T G

R5 1

/4

91

305

480

BR

AC

KE

T, A

IR D

ISC

HA

RG

E A

C30

06 (

RE

V 1

)

10

49

61

504

-09

0N

UT

, T

INN

ER

MA

N 1

/4-2

01

11

974

808

-05

0C

ON

NE

CT

OR

, 1/2

BA

RB

X 1

/2 M

NP

T

12

13

03

815

VA

LV

E,

CH

EC

K 1

/2

13

29

75

200

-02

5IN

SE

RT

, C

OM

PR

SN

FIT

TIN

G 1

/2 B

RA

SS

14

13

02

613

CLIP

, 1/2

" H

YD

HO

SE

HO

LD

ER

15

19

43

103

-02

5R

IVE

T,

PO

P 3

/16

X 1

/2 A

LU

MIN

UM

16

13

05

463

B

RA

CK

ET

, G

AU

GE

& L

IGH

T (

RE

V 2

)

17

19

70

308

-02

5E

LB

OW

, H

YD

1/2

BA

RB

X 1

/4 M

NP

T

18

17

70

413

69

SW

ITC

H,

PR

ES

SU

RE

WIT

H U

NL

OA

DE

R F

19

13

05

162

C

AP

, 7

/8 ID

PL

AS

TC

20

13

05

799

G

RO

MM

ET

, 3/4

OD

X 1

/2 I

D X

1/8

TH

ICK

21

13

04

998

GA

UG

E, 0

-20

0 P

SI 1

/4 M

NP

T L

IQU

ID F

ILLE

D

22

13

07

054

T

EE

, .2

50

MN

PT

X .2

50M

NP

T X

.2

50

FN

PT

NS

1.0

83

FT

890

341

76

TU

BE

, A

IR B

RA

KE

.2

5

14

15

44

6

13

2

12

6

11

1

7

8

10

9

4

21

10

16

87

22

17

18

19

20

5

10/093-3.0.0

AC30A FRAME & PARTSP/N: 200280-999

Pa

rts L

ist

ITE

MQ

TY

PA

RT

NU

MB

ER

DE

SC

RIP

TIO

N

11

970

508

-10

6C

ON

NE

CT

OR

, 1/2

MJ

IC X

-12

MS

AE

21

970

512

-10

6C

ON

NE

CT

OR

, 3/4

MJ

IC X

-12

MS

AE

31

305

479

FR

AM

E, A

C30

06

(R

EV

1)

44

300

540

-00

1IS

OL

AT

OR

, 6

0A

HA

RD

BU

LL

ET

(R

EV

2)

54

300

541

-00

1W

AS

HE

R,

ISO

LA

TO

R 6

0A

HA

RD

(R

EV

2)

62

929

104

-32

5B

OLT

, H

EX

GR

5 1

/4-2

0 X

3 1

/4

74

938

604

-07

1W

AS

HE

R,

FLA

T G

R5 1

/4

81

800

56-1

3-1

2

KIT

, H

YD

VA

LV

E B

LO

CK

13

GP

M F

LO

W C

ON

TR

OL

92

988

912

-10

6P

LU

G,

12 S

AE

PLA

ST

IC

10

49

61

504

-09

0N

UT

, T

INN

ER

MA

N 1

/4-2

0

11

13

04

762

BR

AC

KE

T, V

ALV

E B

LK

35

PIS

TO

N A

(R

EV

2)

12

29

29

104

-10

0B

OLT

, H

EX

GR

5 1

/4-2

0 X

1

13

13

04

930

PL

AT

E,

VIB

RA

TIO

N I

SO

LA

TO

R A

C3

0N

S1

306

812

-21

5O

RIF

ICE

, S

ILV

ER

.2

15

1

2

3

4

5

6

7

8

9

10

11

7

12

13

10

20

028

0-9

99

(R

EV

1)

NO

TE

:W

HE

N R

EP

LAC

ING

HY

DR

AU

LIC

VA

LVE

BLO

CK

(P/N

800

56-1

3-12

),Y

OU

MU

ST

RE

MO

VE

OR

IFIC

E(P

/N 3

0681

2-21

5) F

RO

M T

HE

OLD

BLO

CK

AN

D IN

STA

LL O

N T

HE

NE

W B

LOC

K.

10/093-4.0.0

AC30A CYLINDERS & VALVES

10/09

II = PART OF VALVE KIT III = PART OF PISTON + RINGS + CYLINDER KIT, LOW PRESSURE IV = PART OF PISTON RING KIT VI = PART OF PISTON, CYLINDER HEAD ASSEMBLY LH VI I= PART OF PISTON, CYLINDER HEAD ASSEMBLY RH

ITEM KITS QTY P/N DESCRIPTION1 - 1 N/A CRANKCASE ASSEMBLY2 - 8 755080-001 SCREWED STUD3 III, VI, VII 1 N/A PISTON ASSEMBLY4 III, VI, VII 1 N/A CYLINDER5 - 8 755080-002 WASHER6 III, IV, VI, VII 8 755080-003 LOCK NUT7 III, VI, VII 4 755080-004 PIN8 II, VI, VII 2 N/A SUCTION DISC9 VI, VII 2 755080-005 VAVLE SEAT10 II, VI, VII 2 N/A DELIVERY DISC11 VI, VII 2 755080-006 GUARD12 II, VI, VII 2 755080-007 SPRING13 II, VI, VII A/R 755080-008 CORD14 II, VI, VII 2 755080-009 O-RING15 VI, VII 10 755080-010 BOLT16 VI 1 755080-011 CYLINDER HEAD LLP17 VII 1 755080-012 CYLINDER HEAD RLP18 - 4 755080-013 BOLT19 - 1 REF INLET SILENCER (SEE Aw-461)20 II 2 755080-014 GASKET21 - 4 755080-015 WASHER22 VI 10 755080-002 WASHER23 - 4 755080-016 WASHER24 II 4 755080-017 LOCK NUT

3-4.1.0

AC30A CYLINDERS & VALVES

10/093-5.0.0

AC30A CRANKCASE ASSEMBLY

10/09

CAP755080-037121

GASKET755080-036120

CONNECTING ROD RIGHT755080-0351V19

CONNECTING ROD LEFT755080-0341V18

WOODRUFF KEY755080-0331V17

BOLT755080-032616

BREATHER FLANGE755080-031115

GASKET755080-030114

SIGHT GLASS755080-029113

NIPPLE755080-028112

DOWELL PIN755080-027211

BOLT755080-0261010

O-RING755080-0251V9

RETAINER755080-02418

SEAL755080-0231V7

SEAL755080-0221V6

BEARINH755080-0211V5

BEARING755080-0201V4

CRANKSHAFTN/A1V3

BEARING HOUSING755080-01912

CRANKCASE755080-01811

DESCRIPTIONP/NQTYKITSITEM

V = PART OF CRANKSHAFT + CONNECTING ROD KIT

3-5.1.0

AC30A CRANKCASE ASSEMBLY

10/09

III = PART OF PISTON + RINGS + CYLINDER KIT, LOW PRESSURE

IV = PART OF PISTON RING KIT

VI = PART OF PISTON, CYLINDER HEAD ASSEMBLY LH

VII = PART OF PISTON CYLINDER HEAD ASSEMBLY RH

GUDGEON PIN755080-0391VI, VII7

RING COMPRESSIONN/A1IV6

RING COMPRESSIONN/A1IV5

RING SCRAPERN/A1IV4

CIRCLIP755080-0382III3

PISTONN/A1III2

CONNECTING RODN/A1-1


3-6.0.0

AC30A PISTON ASSEMBLY

10/093-7.0.0

AC30A COOLING SYSTEM

10/09

FLAT GASKET755080-049112

COUPLING755080-048111

CYLINDER HEAD RH755080-012110

BOLT755080-04729

O-RING755080-04628

O-RING755080-0452II, V, VI,VII7

CYLINDER HEAD LH755080-01116

CAPNUT755080-04445

WASHER755080-0438II, V, VI,VII4

BOLT755080-04223

DELIVERY PIPE755080-04112

CONNECTION PIPE755080-04021


II = PART OF VALVE KIT V = PART OF CRANKSHAFT + CONNECTING ROD KIT VI = PART OF PISTON, CYLINDER HEAD ASSEMBLY LH VII = PART OF PISTON, CYLINDER HEAD ASSEMBLY RH

3-7.1.0

AC30A COOLING SYSTEM

10/093-8.0.0

AC30A COOLING FAN ASSEMBLY

10/093-8.1.0

ITEM QTY P/N DESCRIPTION1 1 755080-051 FAN HOUSING2 1 755080-052 FAN3 1 755080-053 HOUSING4 6 755080-054 BOLT5 6 755080-055 WASHER6 1 755080-056 BOLT7 1 755080-057 WASHER8 4 755080-058 TAPTITE BOLT9 1 755080-059 LOCK NUT10 1 755080-060 LABEL11 1 N/A CRANKCASE ASSEMBLY

AC30A COOLING FAN ASSEMBLY

10/093-9.0.0

AC30A AIR INLET ASSEMBLY

10/09

PLUG755080-070114

LOCK NUT755080-059413

WASHER755080-055812

BOLT755080-069411

COVER755080-068110

COVER755080-06719

AIR FILTER7501071I8

FILTER HOUSING755080-06617

O-RING CORD755080-065A/R6

LABEL755080-06415

INLET SILENCER755080-06314

SEAL755080-06223

PIPE755080-06112

CRANKCASE ASSEMBLYN/A11

DESCRIPTIONP/NQTYKITITEM

3-9.1.0

AC30A AIR INLET ASSEMBLY

10/09

PISTON, CYLINDER HEAD ASSEMBLY RH755066VII

PISTON, CYLINDER HEAD ASSEMBLY LH755065VIVII

CRANKSHAFT + CONNECTING ROD KIT755064V

PISTON RING KIT755063IV

PISTON + RINGS + CYLINDER KIT, LOW PRESSURE755062III

VALVE KIT755061II

FILTER KIT755060I

DESCRIPTIONP/NKIT

NOTE:

SEE PAGE 3-4.0.0 THRU 3-9.1.0FOR INDIVIDUAL PARTS CONTAINED IN THESE SERVICE KITS.PARTS OF A SERVICE KIT MAY BE SPREAD OVER SEVERAL LISTS.

3-10.0.0

AC30A SERVICE KITS

10/094-1.0.0

{In

th

e e

ven

t th

at

the u

nit

ru

ns o

ver p

ressu

re,

the s

afety

valv

e w

ou

ld r

ed

uce t

he t

an

k p

ressu

re t

o a

sav

e l

ev

el.

Be s

ure i

t w

ill

wo

rk

pro

perly

. N

ever

ru

n t

he

un

it w

ith

ou

t th

is s

afe

ty v

alv

e.

{D

o n

ot

use p

etr

ole

um

based

or o

ther f

lam

mab

le s

olv

en

ts f

or c

lean

ing

.

{R

ou

tin

e m

ain

ten

an

ce i

nsu

res t

ro

ub

le-free o

perati

on

an

d p

ro

tects

yo

ur i

nv

estm

en

t.

All

warran

ties a

re v

oid

if

main

ten

an

ce i

s n

eg

lecte

d.

CA

UT

IO

N

EV

ER

Y 6

00

0 R

UN

HO

UR

SX

RE

PL

AC

E V

AL

VE

DIS

CS

HIG

H T

EM

PE

RA

TU

RE

S A

ND

EX

TE

ND

ED

SE

RV

IC

E M

AY

SH

OR

TE

N

TH

E T

IM

E B

ET

WE

EN

HY

DR

AU

LIC

OIL

CH

AN

GE

S.

XC

HA

NG

E H

YD

OIL

CH

AN

GE

HY

DR

AU

LIC

SY

ST

EM

FIL

TE

RX

CH

EC

K H

YD

FIL

TE

R

FO

R P

AO

(S

YN

TH

ET

IC

) O

IL

EV

ER

Y 3

00

0 R

UN

HO

UR

S

FO

R M

IN

ER

AL

BA

SE

D O

IL

EV

ER

Y 1

00

0 R

UN

HO

UR

SX

CH

AN

GE

CR

AN

K O

IL

*

RE

PL

AC

E A

IR

FIL

TE

R A

FT

ER

EV

ER

Y 6

00

RU

N H

OU

RS

X

RE

MO

VE

AN

D C

LE

AN

WIT

H C

OM

PR

ES

SE

D A

IR

XIN

SP

EC

T A

IR

FIL

TE

R

ON

-O

FF

PR

ES

SU

RE

S S

HO

UL

D B

E V

ER

IF

IE

D F

OR

CO

NS

IS

TE

NC

Y.

FU

RN

AS

SW

IT

CH

AD

JU

ST

ME

NT

.

XC

HE

CK

SE

TT

IN

GS

SU

DD

EN

CH

AN

GE

IN

PE

RF

OR

MA

NC

E I

ND

IC

AT

ES

A P

RO

BL

EM

MA

Y

BE

DE

VE

LO

PIN

G.

IN

VE

ST

IG

AT

E P

RO

BL

EM

.

XC

HE

CK

CO

MP

RE

SS

OR

OP

ER

AT

IO

N

WIT

H P

OW

ER

OF

F,

OP

EN

DR

AIN

DE

VIC

E T

O P

UR

GE

WA

TE

RX

DR

AIN

AIR

TA

NK

SH

OU

LD

BE

IN

LO

WE

R H

AL

F O

F S

IG

HT

GL

AS

SX

CH

EC

K O

IL

LE

VE

L

NO

TE

S

(W

hen

bo

th r

un

ho

urs a

nd

in

terv

al

are s

ho

wn

, u

se w

hic

hev

er c

om

es f

irst!

)

2

YE

AR

S

1

YE

AR

½

YE

AR

PE

R

MO

NT

H

DA

IL

Y

SE

RV

IC

E P

ER

FO

RM

ED

* R

EC

OM

ME

ND

ED

CR

AN

KC

AS

E O

IL

S:

SE

E I

NIT

IA

L S

TA

RT

-U

P P

RO

CE

DU

RE

NO

TE

: U

se

on

ly a

uth

ori

ze

d p

art

s.

An

y d

am

ag

e o

r m

alf

un

cti

on

ca

us

ed

by

th

e u

se

of

un

au

tho

rize

d p

art

s i

sn

ot

co

ve

red

by

Wa

rra

nty

or

Pro

du

ct

Lia

bil

ity

.

LUBRICATION & MAINTENANCESCHEDULE for AC30A

10/09

COMPRESSOR DOES NOT START.

COMPRESSOR DOES NOT PUMP.

INSUFFICIENT AIR RECEIVERPRESSURE.

INSUFFICIENT PRESSURE ATPOINT OF USE.

CAUSE:No electrical power.Receiver pressure between starting andstopping pressures.

SOLUTION:Check or have electrical system checked.Wait until pressure drops.

CAUSE:Furnas Switch open.Solenoid valve not energized.

SOLUTION:Have electrician check wiring.

CAUSE:Air leak(s).Air intake filter clogged.Air consumption exceeds unit capability.Pressure gauge defective.

SOLUTION:Check for air leak(s) and correct as necessary.Clean or replace intake filter.Decrease demand or add unit.Replace gauge.Disassemble and clean.

CAUSE:Leaks or restrictions.Air filter clogged.Service hose too small.Excessive air requirement.

SOLUTION:Check hose and piping.Clean or replace air filter.Replace with larger hose.

PROBLEM CAUSE/SOLUTION

4-2.0.0

AC30ATROUBLESHOOTING

10/09

PRESSURE IN RECEIVER RISESABOVE MAXIMUMAND CAUSESSAFETY VALVE TO BLOW.

RECEIVER DOES NOT HOLDPRESSURE.

TOO FREQUENT STARTING ANDTOO SHORT OPERATING PERIODS.

HIGH OIL CONSUMPTION.

CAUSE:Furnas switch incorrectly set or out or order.Solenoid valve defective.

SOLUTION:Set switch to stop compressor at ratedmaximum pressure. Replace switch it does notrespond.Remove and test valve on outside mains supplyline. Replace, if out of order.

CAUSE:Discharge check valve leaks.

SOLUTION:Replace.

CAUSE:Air pressure switch incorrectly set.Discharge check valve leaks.High condensate level in receiver.

SOLUTION:Increase pressure.See LOADING PERIODS TOO LONG (page 9-3.0.0).Drain condensate more frequently.

CAUSE:Oil level too high.Breather valve malfunctioning.Piston ring(s) worn or broken.Intake filter clogged.

SOLUTION:Do not overfill crankcase. Keep level withinlower half of sight glass.Check valve.

PROBLEM CAUSE/SOLUTION

4-2.1.0


10/09

LOADING PERIODS TOO LONG

CAUSE/SOLUTION

CAUSE:Excessive air consumption.Compressor not in optimum condition.Sticking or damaged valves.

SOLUTION:Decrease consumption.Have compressor inspected.

PROBLEM

4-2.2.0


10/09

SET UP

1 Install flow meter in Port “A” highpressure line to the hydraulic motor.

2 Install a 3000 psig pressure gauge inPort “A” before the flow meter. Thiswill read system pressure. Install apiece of reflective tape to the drivecoupling at the top access hole.

SYSTEM TEST

1 Engage PTO and raise the truck engineRPM to the proper setting withoutstarting the air compressor. Record themain hydraulic flow through Port “A”and the system pressure. Recordhydraulic motor/compressor RPM witha phototach.

2 With air compressor running, and theair tank pressure anywhere from 30 to100 psig, record the main hydraulicflow through Port “A” and the maxsystem pressure. The main flowshould be a maximum of 12 gallons perminute. The max system pressureshould be 2500 psig on startup andthen from 1800 to 2000 psig whilerunning. The motor flow should be 12gallons per minute.

4-3.0.0


10/09

7 If the air compressor fails to start and the hydraulic pressure is low:

A. Check the red power wire for + 12volts DC.

B. Check to see if the air tankpressure is higher than the systemreset pressure (usually 110 psig).

C. Remove the ventable relief valveand check for contamination holdingthe valve in the open condition.Check for o-ring damage.

8 If the compressor fails to start and the hydraulic pressure is high:

A. Check power to hydraulicsolenoid coil at Furnas switch

9 If the motor flow is 12 GPM and thecompressor is turning less than 1700RPM the motor has degraded enoughto allow hot oil to pass throughwithout producing speed. Rebuild orreplace motor.

4-3.1.0


10/094-4.0.0

VALVE REPLACEMENT PROCEDURE

10/095-1.0.0

60 GALLON RECEIVER TANKw/ SHIP LOOSE KIT

10/09

REDUCER, PIPE --32 NPT/---24 NPTF750490 2 24

NUT, HEX 3/8 NF017100 4*23

WASHER, SP LK 3/8021101 4*22

WASHER, FLAT, 3/8021200 4*21

BOLT, HEX HD 3/8 NF x 2 3/4" LG G5009101 4*20

ELL, BULKHEAD 90º -10 JIC750429 1*19

ELL, 90º -10 FEM SWIVEL/ JIC750479 1*18

HOSE, 10 PUSH-ON, LOW PRESSURE750209-1921*17

FITTING, #10 PUSH-ON/ JIC FEM750430 2*16

TUBE, SUPPORT750202 2 15

NUT, HEX #10015600 2 14

WASHER, SP LK #10019800 2 13

CLAMP, PLASTIC750191 2 12

SCREW, RD HD #10002200 2 11

ELL. 90º - (AIR IN)750428 1 10

VALVE, DRAIN750715 1 9

TUBE, ASSEMBLY750459 1 8

PLUG, 3/4 DRYSEAL PIPE750426 3 7

PLUG, PIPE 1/4 NC000209 1 6

ELL, 90º - (AIR OUT)360263 1 5

REDUCER, PIPE THREAD750423 2 4

FITTING, ELL GAUGE750447 1 3

GAUGE, 0-200 PSI AIR750205-006 1 2

TANK, 60 GAL HORZ RECEIVER750201 1 1

DESCRIPTIONP/NQTYITEM

NOTE: ITEMS MARKED WITH AN ASTERISK (*) ARE CONTAINED IN SHIP LOOSE KIT P/N 750186.

5-1.1.0


10/095-2.0.0


10/09

NUT, HEX 3/8 NF017100 4*23

WASHER, SP LK 3/8021101 4*22

WASHER, FLAT, 3/8021200 4*21

BOLT, HEX HD 3/8 NF x 2 3/4" LG G5009101 4*20

ELL, BULKHEAD 90º -10 JIC750429 1*19

ELL, 90º -10 FEM SWIVEL/ JIC750479 1*18

HOSE, 10 PUSH-ON, LOW PRESSURE750209-1921*17

FITTING, #10 PUSH-ON/ JIC FEM750430 2*16

TUBE, SUPPORT750202 2 15

NUT, HEX #10015600 2 14

WASHER, SP LK #10019800 2 13

CLAMP, PLASTIC750191 2 12

SCREW, RD HD #10002200 2 11

ELL. 90º - (AIR IN)750428 1 10

VALVE, DRAIN750715 1 9

TUBE, ASSEMBLY750459 1 8

PLUG, 3/4 DRYSEAL PIPE750426 3 7

PLUG, PIPE 1/4 NC000209 1 6

ELL, 90º - (AIR OUT)360263 1 5

REDUCER, PIPE THREAD750423 2 4

FITTING, ELL GAUGE750447 1 3

GAUGE, 0-200 PSI AIR750205-006 1 2

TANK, 30 GAL HORZ RECEIVER750200 1 1


NOTE: ITEMS MARKED WITH AN ASTERISK (*) ARE CONTAINED IN SHIP LOOSE KIT P/N 750186.

5-2.1.0


10/09

SP LK WASHER 1/4020200 4 *9

HEX HD SCREW 1/4 NC x 1 1/2005800 4 *8

PLASTIC TUBING340959 1 *7

BULKHEAD UNION750445 1 *6

#2 NPT / #4 COM BRASS ADAPTER750444 1 5

#10 JIC FEM FITTING750430 2 *4

90º ELBOW7504042 3

HOSE750209 1*2

FILTER/REG/LUB ASSEMBLY (see page 6-1.1.0)7502051 1


* THESE ITEMS CAN BE PURCHASED AS SHIP LOOSE KIT P/N 750206

6-1.0.0

AIR MOISTURE SEP/FILTER (KIT)P/N: 750829

10/09

* THESE ITEMS ARE NOT INCLUDED IN P/N 7502005 AND ARE NOT SHOWN ON ILLUSTRATION

*THESE ITEMS ARE NOT INCLUDED IN P/N 750205 AND ARE NOT SHOWN ON ILLUSTRATION.

SEAL KIT COMPLETE w/ O-RINGS, SEALS,ELEMENT

750205-014 *11

STANDARD 5 MICRON FILTER750205-010 *10

REPLACEMENT/MAINTENANCE PARTS

SLEEVE750205-009 2 9

SLEEVE w/ MTG BRACKET750205-008 2 8

1/2” NPT END750205-007 1 7

GAGE 0-160 PSI750205-006 1 6

AUTO DRAIN750205-005 1 5

SHUT OFF VALVE750205-004 1 4

LUBRICATOR750205-0031 3

REGULATOR750205-002 1 2

FILTER750205-001 1 1


6-1.1.0

FILTER/REGULATOR/LUBRICATORASSEMBLY P/N: 750205

10/09

NOTE: F/R/L IS PURCHASED AS AN ASSEMBLY; (-XXX) DASHNUMBERS ARE FOR REPLACEMENT PARTS.

6-2.0.0

O-RING, FILL PLUG751277-012112

BOWL O-RING751277-011211

METAL BOWL (LUB)751277-010110

METAL BOWL (F/R)751277-00919

AUTO MECH DRAIN (F/R)751277-00818

FILTER ELEMENT751277-00717

PRESS, GAUGE 0-300 PSI751277-00616

END BLOCK, 3/4 NPT751277-00555

SAFETY LOCKOUT VALVE751277-00414

JOINER SET w/ T-BRKT751277-00323

LUBRICATOR751277-00212

FILTER/REGULATOR751277-00111


FILTER/REGULATOR/LUBRICATORP/N: 751277

10/097-1.0.0

AC30A WEATHER GUARDINSTALLATION

10/09

ITEM QTY P/N DESCRIPTION1 1 750212 HOSE REEL2 1 750212-002 GUIDE ARM ASSEMBLY (REF.)3 1 750212-003 SWIVEL ASSEMBLY (REF.)

7-2.0.0

HOSE REEL 1/2" x 50’P/N: 750212

10/09

NOTE: THIS PART IS USED WHEN HOSE REEL IS INSTALLED IN A BODYCOMPARTMENT AND HOSE IS TO EXIT THRU THE BODY.

7-3.0.0

HOSE ROLLER GUIDEP/N: 750213

10/09

P.O. Box 580697 * Tulsa, OK 74158-06974707 N. Mingo Rd. * Phone (918) 836-0463

LIMITED WARRANTY2 YEAR PARTS AND LABOR

Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the dateof purchase. Each new Auto Crane unit they sell will be free under normal use and service fromdefects in material and workmanship. Date of purchase will be honored as the date indicated onthe Bill of Sale, which must accompany the Warranty Registration and be on file with AutoCrane. Absent a valid Warranty Registration and appropriate documentation, the original dateof manufacture, as indicated by the serial number on the product, will be used to determine theeffective date of the 2 year warranty.

The obligation of Auto Crane under this warranty is limited to the replacement or repair of partsthat appear to the manufacturer after review and/or inspection to be defective and paid flat ratelabor for replacing defective parts. This warranty does not obligate Auto Crane to bear the traveltime charges in connection with the replacement or repair of defective parts. Responsibility forcustomer’s claims arising from misapplication, abuse, misuse or alteration of equipment orparts lies with the distributor or user and no warranty obligation is assumed in these circumstancesby Auto Crane.

Auto Crane will in no event be liable for any consequential damages or contingent liabilitiesarising out of the failure of any Auto Crane Product or parts to operate properly.

Auto Crane makes no warranty in respect to component accessories, it being subject to thewarranties of their respective manufacturers.

If field service, at the request of the distributor, is rendered and fault is found not to be with AutoCrane’s product, the distributor shall pay the time and expense of the field representative.

Claims for service labor or other expenses that have incurred by the buyer without approval orauthorization or Auto Crane will not be accepted.

When applying for warranty, claims may be handled by contacting your nearest authorized AutoCrane Distributor. All claims are to be filed in writing on an Auto Crane Warranty ClaimForm.

AUTO CRANE COMPANY IS UNDER NO OLIGATION TO EXTEND THIS WARRANTYTO ANY CUSTOMER FOR WHICH AN AUTO CRANE DELIVERY REPORT FORMHAS NOT BEEN COMPLETED AND ON FILE WITH AUTO CRANE COMPANY

Limited Warranty 2 Years Effective September 2, 2003

AC30A COMPRESSOR OWNERS MANUAL - Auto Cranecompressor when the compressor is running only. This is a...

Documents

Transcript of AC30A COMPRESSOR OWNERS MANUAL - Auto Cranecompressor when the compressor is running only. This is a...