Makita MAC5500G User manual

MODEL # SERIAL #
Portable Gas
Compressor
Operating
Instructions
Carefully read this instruction manual before
attempting to operate this compressor.
NOTICE
www.makita.ca
MAC5500G

www.makita.ca
Wear hearing protection.
Wear eye protection.
Wear respiratory protection.
Read the instruction manual
GX
HONDA
MAC5500G

3
CAREFULLY READ THIS
INSTRUCTION MANUAL BEFORE
ATTEMPTING TO OPERATE
THIS COMPRESSOR.
SAFETY PRECAUTIONS ................................................................................. 4
Cautions ..................................................................................................... 4
Air receiver.................................................................................................. 4
Safety valve ................................................................................................ 4
INSTALLATION & OPERATING INSTRUCTIONS........................................... 5
Installation .................................................................................................. 5
Before operating the air compressor .......................................................... 5
Compressor lubrication............................................................................... 5
Filling compressor with oil .......................................................................... 6
Oil changes................................................................................................. 6
Engine lubrication ....................................................................................... 6
Maintenance............................................................................................... 6
Checking Belt Tension................................................................................ 7
OPERATING YOUR AIR COMPRESSOR........................................................ 8
Engine Gas Driven ..................................................................................... 8
COMPRESSOR MAINTENANCE SCHEDULE ................................................ 9
TROUBLE SHOOTING................................................................................... 10
WARRANTY.................................................................................................... 15
FACTORY SERVICE CENTRES..................................................................... 34
PART BREAKDOWNS ................................................................................... 35
En Français ..................................................................................................... 17
TABLE OF CONTENTS

4
SAFETY PRECAUTIONS
Please familiarize yourself with the following information to prevent
damage to your compressor unit and injury to the operator.
CAUTIONS
The air compressor and engine will get hot while in
operation. Never touch the discharge tubing, engine
or compressor pump while in operation. The
compressor operates automatically while the engine is running.
WARNING
CAUTION
Compressed air from the unit may contain hazard-
ous fumes. Air produced by this compressor is not
suitable for breathing purposes. Always use a res-
pirator when spraying paint or chemicals, or when sandblasting. Always
wear safety glasses or goggles when using compressed air.
It is not practical or possible to warn you about all the hazards associated
with operating or maintaining this equipment. You must use your own
good judgment.
AIR RECEIVER
Over pressurizing the air receiver could cause personal injury or material
damage. To protect from over pressurizing, a factory pre-set safety valve
is installed.
-
tions as the original equipment. Please contact the authorized dealer for

NEVER WELD, DRILL OR CHANGE
THE AIR RECEIVER IN ANY WAY
SAFETY VALVE
DO NOT REMOVE,
MAKE ADJUSTMENTS TO
OR SUBSTITUTE THIS VALVE!
Adjustment by user will automatically void the warranty.
This valve is factory installed to prevent over pressurizing of the air

should never be tampered with.

5
INSTALLATION & OPERATION
INSTALLATION
Proper care, maintenance and lubrication ensures longevity. The com-
pressor should always be level for proper lubrication. Use only in a clean,


Do not place rags or other materials on top of the compressor, as this

BEFORE OPERATING THE AIR COMPRESSOR
1) Check to see that nuts and bolts are all snug.
2) Check if the quantity and quality of oil is correct.
3) 
PLEASE CHECK THE FOLLOWING CAREFULLY:
COMPRESSOR LUBRICATION
ALWAYS CHECK THE OIL LEVEL AND
QUALITY BEFORE START–UP. DO
NOT ADD OR CHANGE OIL WHILE
THE UNIT IS RUNNING.USE ONLY
RECOMMENDED NON-DETERGENT OIL.
RECOMMENDED OIL.
Compressor oil: #EAOIL 10 (1 Litre)
Compressor oil: #EAOIL 40 (4 Litres).
* Compressor originally lled with SAE 20W oil (ISO 68)
Compressor oil is a non-detergent mineral oil formulated with additives to
help minimize carbon build-up, increase ring life and reduce oil consump-
tion, for use at ambient temperatures of 0° to 30°C (32°F - 86°F).

6
INSTALLATION & OPERATION
OTHER APPROVED OILS.
Regular mineral oils can also be used in Makita compressors. Always

AMBIENT TEMPERATURES AT
POINT OF OPERATION
SAE VISCOSITY ISO VISCOSITY
-16°C TO 0°C (3.2°F - 32°F) SAE 10W ISO 32
1°C TO 26°C (33.8°F - 78.8°F) SAE 20W ISO 68
ABOVE 27°C (80.6°F) SAE 30W ISO 100
FILLING THE COMPRESSOR WITH OIL
1) 
2) Slowly pour the proper oil into the pump crankcase.
3) Always keep oil level in the middle of the sight glass.
OIL CHANGES
CHANGE OIL EVERY 300 HOURS OR 3 MONTHS
WHICHEVER COMES FIRST.
1) Remove the oil drain plug. Allow oil to drain completely.
2) Replace the oil drain plug.
3) 
INITIAL OIL CHANGE DUE AT 100 HOURS.
ENGINE LUBRICATION
Check engine Owner’s manual for lubrication and maintenance
requirements.
MAINTENANCE
Before doing any maintenance or adjustments to your air compressor,

►TURN OFF ENGINE. WAIT UNTIL ENGINE IS COMPLETELY
STOPPED.
►DRAIN AIR RECEIVER AND AIR LINES OF AIR PRESSURE.

7
INSTALLATION & OPERATION
CHECKING BELT TENSION
Adjust belt(s) so when pressure is applied at the center, there is approxi-
mately 1/2” slack (see diagram “Figure A” below).
Centre Distance
Too Loose
Too Tight
Slight Bow
Correct Tension
If the belt is in-
stalled too tight,
the engine might
be overloaded.
This will cause
the engine to
overheat. If the
belt is installed
too loosely, it will
slip and excessive
wear and vibration
will occur.
Figure A
1) Turn off engine. Wait until engine is completely stopped
2) Remove belt guard.
3) Loosen engine bolts and slide engine toward compressor head
just enough to allow old belt to be removed.
4) Install proper replacement belt.
5) Slide engine away from compressor head to provide recommend-
ed tension as shown in diagram (Figure A.)
6) Align belt using a straight edge ruler against pulley’s edge.
7) Fasten engine bolts.
8) Ensure engine and compressor pulley’s are secure. Re-check
alignment.
9) Re-install belt guard.
10) Belt tension should be checked after 20 hours of operation.
Check tension monthly thereafter.
HOW TO INSTALL A NEW BELT IF REQUIRED:

8
OPERATING YOUR AIR COMPRESSOR
ENGINE - GAS DRIVEN
1) Check entire unit for any damage.
2) 
3) 
4) Read entire engine manual.
5) Starting the engine.
a) Move fuel lever to the “On” position.
- If engine is cold, move choke lever to the “Closed” position
- If engine is warm, leave choke lever in “Open” position
b) Turn engine switch to “On” position.
c) Pull starter grip lightly until you feel resistance, then pull briskly,
return starter grip gently - engine should start, if not repeat.
d) Once the engine starts running, slowly move the choke lever to
the “Open” position.
e) 
receiver with compressed air, when maximum pressure (set by
the pilot valve control) is reached, the engine and compressor will
slow down to idle speed, and will return to full RPM when the cut-
in pressure is reached. The unit will continue to cycle automati-
cally until turned off.
6) Stopping the engine.
a) Turn engine switch to the “Off” position.
b) Turn the fuel lever to the “Off” position.
ENGINE IDLE SPEED MAY NEED
TO BE ADJUSTED, EVEN ON YOUR
BRAND NEW UNIT TO COMPEN-
SATE FOR DIFFERENCES IN
ALTITUDE. PLEASE CONSULT THE
ENGINE OPERATING MANUAL.

9
EXTRA CARE SHOULD BE TAKEN
TO AVOID PERSONAL INJURIES
WITH AUTOMATICALLY CON-
TROLLED COMPRESSORS
MAINTENANCE SCHEDULE
DAILY OR BEFORE EACH USE
►CHECK OIL LEVEL.
►DRAIN CONDENSATION FROM AIR RECEIVER.
►CHECK FOR ANY UNUSUAL NOISE OR VIBRATION.
►BE SURE ALL NUTS AND BOLTS ARE TIGHT.
WEEKLY
►TURN OFF ENGINE. CLEAN DUST AND FOREIGN MATTER
FROM CYLINDER HEAD, ENGINE, FAN BLADES, INTER-
COOLER AND AIR RECEIVER.
►CLEAN AIR FILTER BY OPENING AIR FILTER, REMOVING
FILTER ELEMENT AND CLEANING IT THOROUGHLY WITH
SOAPY WATER. RINSE THOROUGHLY AND ALLOW TO DRY
COMPLETELY BEFORE ASSEMBLY.
►WORN FILTERS SHOULD BE REPLACED.
►CHECK V-BELTS FOR WEAR.
MONTHLY
►INSPECT UNIT FOR LEAKS.
►TIGHTEN JOINTS IF LEAKS ARE OBSERVED.
►CHECK V-BELTS FOR PROPER TENSION.
►CHECK COMPRESSOR PULLEY AND ENGINE SHEAVE ARE
ALIGNED AND SECURELY FASTENED.
QUARTERLY OR 300 HOURS (Whichever comes rst)
►INSPECT THE AIR RECEIVER FOR CORROSION OR OTHER
DAMAGE.
►CHANGE COMPRESSOR OIL.
►REPLACE AIR FILTER (MORE OFTEN IF COMPRESSOR IS
USED NEAR PAINT SPRAYING OPERATIONS OR IN DUSTY
ENVIRONMENTS).

10
TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Will not start Please refer to Honda manual
included
Low pressure Safety valve leaks. Replace safety valve.
Drain cock open. Close drain cock.
 
 Clean or replace as necessary.
Defective unloader valve. Replace unloader valve.
Oil in
discharge
Too much oil in the crank-
case.

Improper oil viscosity. drain and replace oil
Compressor overheated. Air pressure regulated too
high.
 
Worn piston rings. Replace piston rings.
Compressor
overheats
Dirty compressor head, cylin-
der or intercooler.
Clean with compressed air.
 Clean or replace as necessary.
Operating pressure too high. Reduce operating pressure.
Low oil or wrong oil being
used.
Drain and replace oil.
Compressor cycle too long.
Proper cycle is 50-60% on
Stop/Start operation.
Allow for longer rest between
cycles.
Compressor
loads & un-
loads or idols
up & down
excessively
Pilot valve differential adjust-
ed too close.
Leaks in air system.
Replace worn components as
necessary.
Make necessary adjustments.
Check for leaks.
Worn or loose drive belts Tighten V-belts or replace
Defective compressor valves. Replace valves.
Compressor too small for
intended use.
Upgrade to larger compressor.