HILL PUMPS EC-3000 User manual

1
EC-3000 Service & Maintenance Manual
REV 2
This manual describes how to perform the servicing and maintenance of the EC-3000 Hill
Compressor.
TABLE OF CONTENTS
Overview..................................................................................................................................................2
Model Specification .................................................................................................................................3
Maintenance Schedule.............................................................................................................................3
Theory of Operation.................................................................................................................................4
Troubleshooting Chart.............................................................................................................................5
Safety .......................................................................................................................................................6
Maintenance............................................................................................................................................7
1 - How to disassemble and change the compressor side valves .......................................................8
2 - How to disassemble and change the compressor final stage valve.............................................13
3 - How to check and change the piston O-rings...............................................................................16
4 - How to change the oil...................................................................................................................21
5 –Crank case maintenance..............................................................................................................22
6 –Replacing burst disc .....................................................................................................................24
Fuses ......................................................................................................................................................24

2
Overview

3
Model Specification
MODEL
CODE
VOLTAGE
Hz
POWER
UK
3000-001
230
50
0.75 kW
US
3000-002
115
60
0.75 kW
EU
3000-003 (004)
230
50
0.75 kW
AUS
3000-005
230
50
0.75 kW
Maintenance Schedule
OPERATION
TIME PERIOD
Change crank oil.
50 hours running time or 1 year's use.
Whichever comes first.
Replace ball valves.
50 hours running time or if compressor
function decreases.
Replace piston O-rings.
When required.
Replace or clean final stage valves.
When pressure release valve hisses
Replace side bullet valves.
50 hours running time or if compressor
function decreases.

4
Theory of Operation
The compressor has three stages of compression. Each stage compressing the air to a
higher pressure than previous.
A. The user activates the compressor with the power switch on the side of the machine and
attaches the compressor to the cylinder.
B. The user selects the desired units and fill pressure.
C. The user starts the compressor. The motor is switched on via a relay and pressure builds.
a. The pressure and temperature are constantly monitored via sensors.
b. When the temperature goes above 75 degrees Celsius the filling will pause and
restart when 65 degrees Celsius is reached.
c. Once the desired pressure is released the compressor stops filling.
D. Air is taken through the inlet filter into stage one.
E. The air passes into stage 2 and is further compressed.
F. The air passes through a filter and into stage 3 and is further compressed.
G. The air is passed into a water separator which removes the majority of moisture from the
air.
H. The air passes from the compressor into the cylinder

5
Troubleshooting Chart
SYMPTOMS
CAUSES
POSSIBLE REMEDY
Air coming out of pressure
release valve.
Pressure will not exceed ~100
Bar.
•Issue with top stage
valve
•Piston O-ring
deteriorated
•Unscrew the bleed
screw slightly to
introduce a slight leak.
Allow the compressor
to run for 10 minutes.
•Clean top stage valve
•Replace piston O-ring.
Compressor no longer making
pressure or very slow.
•Ball valve in
compressor
deteriorated.
•Replace ball valve.
Compressor stalling at higher
pressures.
•Ball valve in
compressor
deteriorated.
•Issue with top stage
valve
•Clean top stage valve
•Replace piston O-ring.
•Replace ball valve.
Compressor leaking /
depressurizes without
opening bleed screw.
•Quick release fitting
worn.
•Seal failure
•Replace quick release
fitting.
•Use leak detector to
locate.
Loud bang and compressor
starts leaking.
•Burst disc failure.
•Replace burst disc.

6
Safety
IMPORTANT
THIS PRODUCT IS DESIGNED TO FILL PRE-CHARGED PCP AIR GUNS AND PAINTBALL GUNS DIRECTLY.
IT CAN ALSO BE USED TO TOP UP SMALL TANKS, BUDDY BOTTLES, AND CYLINDERS UP TO 7 LITRES.
LARGE CYLINDERS AND TANKS ABOVE 4 LITRES SHOULD ONLY BE FILLED BY COMPETENT OR
QUALIFIED PEOPLE
NOT FOLLOWING THE INSTRUCTIONS OR MISUSE OF THE COMPRESSOR WILL VOID YOUR
WARRANTY AND MAY RESULT IN DEATH OR INJURY
DANGER OF EXPLOSION
FROM OVERFILLING OF COMPRESSED AIR BOTTLES
DO NOT EXCEED MAXIMUM FILL PRESSURE OF YOUR CYLINDER AT ROOM TEMPERATURE
ONLY FILL CYLINDERS THAT ARE IN GOOD CONDITION AND ARE IN DATE OF INSPECTION
IMPORTANT
READ ALL INSTRUCTIONS BEFORE USE TO PROTECT YOUR EYES. YOU SHOULD ALWAYS WEAR SAFETY
GLASSES WHEN OPERATING THIS COMPRESSOR AND HEARING PROTECTION WHEN BLEEDING
WARNING
THIS COMPRESSOR PRODUCES CLEAN AIR SUITABLE FOR FILLING PCP AIRGUNS IT DOES NOT
COMPRESS AIR SUITABLE OR CERTIFIED FOR BREATHING APPARATUS. DO NOT USE IT TO FILL SCUBA
TANKS THAT MAY LATER BE USED FOR BREATHING
DANGER OF ELECTRIC SHOCK
DO NOT OPERATE IN THE RAIN OR WITH WET HANDS OR CLOTHES
DANGER
PARTS OF THIS COMPRESSOR GET VERY HOT
WARNING
DO NOT TOUCH MOVING PARTS FOR EXAMPLE THE COOLING FAN.KEEP FINGERS AND LOOSE
CLOTHING AWAY FROM MOVING PARTS
OPERATING TEMPERATURE
+5℃to 75℃(41℉to 167℉)
THERMAL PROTECTION WILL NOT ALLOW COMPRESSOR TO START OUTSIDE THIS RANGE

7
Maintenance
ALWAYS ENSURE BLEED SCREW IS FULLY UNDONE AND COMPRESSOR IS DISCONNECTED FROM
THE CYLINDER BEFORE UNDERTAKING MAINTENANCE.
ENSURE COMPRESSOR IS SWITCHED OFF & UNPLUGGED.
The cowl should be removed before any maintenance.

8
1 - How to disassemble and change the compressor side valves
During use the valves of the compressor will gradually wear. The EC -3000 has several
internal filters that stop any debris entering the compressor or the item you are
filling. The valves will eventually need replacing at the right time to keep the
compressor in optimal condition.
1. Remove pipe on right hand side of compressor head.

9
2. Remove bottom right ball valve housing.
3. Remove the ball from the compressor. It may be necessary to use a small object such as a
craft knife to remove the ball from the compressor.

10
4. Remove the middle right bullet valve housing.
5. Remove pipe on left hand side of compressor head.

11
6. Remove bottom left bullet valve.
7. Remove middle left ball valve. It may be necessary to use a small object such as a craft knife
to remove the ball from the compressor.
8. Replace bullet valves and tighten valves into compressor.
9. Replace balls.

12
a. Apply a dab of silicon grease onto both ball valve housings. To hold balls to the valve
housing.
b. Tighten both bullet valves into compressor.
10. Tighten tubes onto compressor head.
a. Ensure pressure nuts are not overtightened but are done up securely.

13
2 - How to disassemble and change the compressor final stage valve
Cleaning or replacing parts in the final stage valve is often required if air is being
ejected from the pressure release valve.
1. Remove pipe on top of compressor.
2. Remove final stage valve.

14
3. Remove final stage bullet valve. It may be necessary to use a small object such as a craft
knife to remove the valve from the compressor.
a. Ensure that any debris or dirt is removed. If the valve is worn, replace.
4. Remove final stage housing.

15
5. Remove final stage disc valve.
a. Ensure that any debris or dirt is removed. If the valve is worn, replace.
b. Ensure that that the disc valve is not bent whilst removing it.

16
3 - How to check and change the piston O-rings
1. Remove all tubes from the compressor.
2. Remove 6 M5 bolts from compressor head.

17
3. Slide up top section.
a. Check the piston O-rings and replace if necessary.
4. Slide up bottom section and slide up O-ring.

18
5. Remove dowel pin with suitable tool.

19
6. Slide up piston and inspect stage 2 O-ring.

20