Powerbuilt AC5025 Manual

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TABLE OF CONTENTS
Thank You For your Purchase ....................................................................................................................................... 3
Unpacking Your New Compressor ............................................................................................................................... 3
Hazards and Safety ......................................................................................................................................................... 4
Work Area Safety .......................................................................................................................................................... 4
Personal Safety ............................................................................................................................................................. 4
Electrical Safety ............................................................................................................................................................ 5
Air compressor Safety ................................................................................................................................................... 5
Technical Description..................................................................................................................................................... 5
Compliance Plate .......................................................................................................................................................... 6
Performance and Duty Cycle ........................................................................................................................................ 6
Input Plug ...................................................................................................................................................................... 7
Operating Environment ................................................................................................................................................. 7
Machine Layout ............................................................................................................................................................... 8
Assembly ....................................................................................................................................................................... 10
Installing Feet .............................................................................................................................................................. 10
Installing wheels .......................................................................................................................................................... 10
Installing Air Filter ....................................................................................................................................................... 10
Installing Handle ......................................................................................................................................................... 11
Filling Compressor with Oil ......................................................................................................................................... 11
Starting and Stopping .................................................................................................................................................. 12
Checking the Safety Relief Valve ................................................................................................................................ 12
Air Pressure Regulation and Hose Connection ......................................................................................................... 13
Maintenance .................................................................................................................................................................. 14
Replacing Pump Oil .................................................................................................................................................... 14
Cleaning / Replacing Air Filter .................................................................................................................................... 14
Draining the Tank ........................................................................................................................................................ 15
Non-return Valve ......................................................................................................................................................... 15
Belt Adjustment ........................................................................................................................................................... 16
Trouble shooting ........................................................................................................................................................... 17
Warranty Statement ...................................................................................................................................................... 18
Exploded Diagram ........................................................................................................................................................ 19
Parts List ........................................................................................................................................................................ 20
Notes .............................................................................................................................................................................. 21

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WARNING HAZARDS AND SAFETY
Read all safety warning and all instructions.
This Operating Manual has been designed to instruct you on the correct operation of your Powerbuilt product.
Your satisfaction with this product and its safe operation is our ultimate concern. Therefore, please take the
time to read the entire manual, especially the safety symbols and instructions They will help you to avoid
potential hazards that may exist when working with this product. Every effort has been made to ensure that
information
in this manual is accurate and current. However, we reserve the right to change, alter, or otherwise improve the
product and this document at any time without prior notice. Failure to follow the warning and instructions may
result in electric shock, fire and or serious injury to you or others
Save this manual for future reference.
WORK AREA SAFETY
• Ensure your work area is clear, dry, and free of trip hazards.
• Do not operate the compressor in dangerous environments.
• Ensure the area is well ventilated, and all flammable materials are removed to a safe distance, normal
sparking of the electrical motor could ignite fumes.
• Keep children and other visitors away. Do not let children or others contact the compressor, electrical lead,
or air leads.
• Never leave your compressor running unattended.
• Keep guards in place and in working order. Never operate this product with any guard or cover removed.
Make sure all guards are intact and operating properly before each use.
• Remove adjusting tools and wrenches. If any adjustments or maintenance has been performed, make sure
that all tools and adjusting wrenches are removed from product before use.
• Keep the work area clear of all persons, particularly small children, and pets.
• Only use product for its intended use.
• Don’t force product or attachment to do a job it was not designed for.
PERSONAL SAFETY
• Use proper clothing. Wear long pants and long sleeves. Do not wear loose clothing, neckties, or jewelry. They
can get caught and draw you into moving parts. Rubber gloves and nonskid footwear are recommended
when working outdoors. Do not operate the equipment while barefoot or when wearing sandals or similar
lightweight footwear.
• Always wear proper eye protection with side shields marked to comply with the correct AS/NZS STANDARDS
Following this rule will re-duce the risk of serious personal injury.
• Also wear protective hair covering to contain long hair.
• Stay alert, watch what you are doing. Do not use this tool when you are tired.
• Protect your lungs, wear a dust mask when operating product in dusty environments.
• Protect your hearing, wear hearing protection during extended periods of operation.
• Do not overreach. Keep proper balance and footing at all times.
• Use only recommended accessories with this product. The use of improper and or modified accessories may
cause risk of injury.

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ELECTRICAL SAFETY
ELECTRICITY CAN KILL
• Guard against electrical shock by preventing body contact with grounded surfaces, e.g., pipes, radiators,
ovens, refrigerator enclosures.
• Do not abuse cord. Never carry or drag the compressor by the cord or yank it to disconnect from wall socket.
Keep cord away from heat, oil, and sharp edges. Do not drive over or place heavy objects on electrical cord.
• Should any electrical component of the compressor fail to perform properly, shut off the power switch, remove
the plug from the power source and replace/repair before resuming operation.
• Do not expose compressor to rain or wet conditions. Water entering the electronics will increase the risk of
electric shock and damage the compressor.
• it is recommended that the compressor be connected to an RCD.
AIR COMPRESSOR SAFETY
WARNING
• This air compressor does not produce breathable air. Breathing compressed air is dangerous and can
cause harm.
• Hot surfaces are present. DO NOT touch the motor, cylinder, heads and tubes as harm may occur from
burning.
• DO NOT use in potentially explosive atmospheres. Ensure that the atmosphere is free from combustible
gases and high concentrations of fine dust.
• Never apply the outlet air of this compressor directly on to any part of a person’s body. Do not attempt to
block the air outlet with your finger or any part of your body.
• Do not attempt to adjust the pressure switch or the release valve located under the pressure switch
cover.
• Drain the moisture from the tank after use. It will help prevent corrosion and increases tank capacity.
• Pull the ring on the safety valve daily to ensure that it is operating properly and to clear any possible
• debris from the outlet.
• Keep the compressor at least 300mm from the nearest wall to ensure adequate ventilation for cooling
purposes.
• Before transporting the compressor make sure that the pressurized air is bled from the tank and that
the compressor is firmly secured.
• Protect the air hose and electrical lead from damage. Inspect for weak or worn spots regularly and replace if
• necessary.
• Always plug the compressor directly into the electrical outlet.
• Avoid using an extension cord with this product. Use additional air hose instead of an extension cord
to prevent power loss and possible damage to the motor.

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TECHNICAL DESCRIPTION
SPECIFICATION
UNITS
AC5025
Drive
Belt Drive
Motor
Winding
Copper
Tank Size
L
50
Horsepower
HP
2.5
Motor RPM
RPM
2850
Pump RPM
RPM
1030
Air Pressure
PSI
0-120
Displacement
CFM
312 L/min
(11 CFM)
Free Air Delivery
@ 90 PSI
238 L/min
@ 90 PSI
Bar
Bar
8
Wheel Size
mm
200
Voltage
230V/50Hz
Plug
AMPS
10A
N.W
Kg
52
G.W
Kg
56
Size (L x W x H)
mm
860 x 380 x 720
PERFORMANCE AND DUTY CYCLE
This medium duty compressor is not designed for continuous use, spray equipment or heavy-duty air tools.
Attempting to use air tools with a requirement of over 238L/min Free air delivery will reduce the performance of the air
tool.
Pressure Cycle
The compressor forces air into a storage tank, increasing the pressure until it reaches an upper pressure limit at
which the compressor shuts off. When the compressed air is being used by a tool the pressure decreases until the
tank reaches its lower pressure limit, at that point the compressor turns on (via the pressure switch) to re-pressurize
the tank. This is the compressor pressure cycle.
Compressing air produces heat if the compressor is used outside its duty cycle and the heat is not managed the
compressor will be damaged. When the compressor turns off (via the pressure switch, after reaching maximum tank
pressure) it has time to cool down while the air in the tank is being consumed. When a tool consumes the stored air
quickly the time for cool down is reduced because the unit needs to restart to repressurize. If too short a time is
dedicated to the cool down phase the compressor can overheat and become damaged.
Duty Cycle
The ratio between the pressurization and cool down phases is called the Duty Cycle.
To determine whether we need a Trade or DIY compressor we must first understand duty cycles. The duty cycle is a
10 min test. How long over a 10min period is the pump/tool running for.
• 2 min on – 3 min rest – 2 min on – 3 min rest = 40% Duty Cycle.
• 5 mins on – 5 mins rest = 50% Duty Cycle.
• 1 min 30 sec on 8 mins 30 sec rest = 15% duty cycle.

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Whilst running a vehicle in the red zone all the time is great to get you where you need fast!! It dramatically shortens
the life of the vehicle’s engine. The same is said with duty cycles – to obtain the best life and performance out of your
tool or compressor purchase a compressor that suits your application. If you think you’ll be using high air consumption
tools in a continuous manner consider a compressor with a higher FAD rating and/or larger storage tank to reduce the
risk of wearing out or overheating the unit.
Direct Drive compressors: have the pump joined directly to the motor. This means the pump runs at 2800 RPM with
a short piston stroke. This style of compressor has a duty cycle of 30-40% or is designed to run for short periods of
continuous use – no more than 10mins of continuous pumping.
Belt Drive compressors: have the pump and motor separated. This allows the pump speed to be reduce to
1030RPM and allows for increased piston stroke, resulting in larger air deliveries compared to the direct drive style.
Due to the slower speeds of the pump the compressor will produce cooler air with less moisture. Belt drive
compressors have increased duty cycles 50-60%.
INPUT PLUG
The compressor is fitted with a 10amp plug. This machine is designed to work with 10amp wall sockets. It is
important that the machine is plugged directly into the mains plug.
Avoid using an extension cord with this product. Use additional air hose instead of an extension cord. Using extension
cords will reduce the input voltage (known as voltage drop) and this will void the warranty of your machine.
Any modification to the 10amp plug on this compressor will void warranty.
OPERATING ENVIRONMENT
• Operating temperature: -10℃~40℃.
• Transportation and storage: -25℃~55℃.
• Relative air humidity: 40℃ ≤ 50%; 20℃ ≤ 90%.
• The dust, acids, corrosive gases and substance in the ambient air must be not higher than normal level.
• Altitude must be less than 1km.
• Good ventilation around the machine, at a distance of at least 300mm around.
• Compressor must be kept on a level surface to reduce the risk of the machine falling.

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TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SOLUTION
Compressor does not run
No Electrical power
Check unit is plugged in and power point
turned on
Check fuse/circuit breaker
Motor overload protection has tripped
Ensure compressor is plugged directly
into the wall socket – not extension lead
Let motor cool and overload protection
switch will reset
Faulty pressure switch
Replace pressure switch
Tank is full of air
Compressor will only turn on when tank
pressure drops to below cut in pressure
Faulty capacitor in motor
Return to Reseller/Authorized Service
agent for inspection and repair
Faulty motor
Return to Reseller/Authorized Service
agent for inspection and repair
Compressor runs continuously
Faulty pressure switch
Return to Reseller/Authorized Service
agent for inspection and repair
Excessive air usage
Reduce air usage, compressor may not
be large enough for tools requirements –
refer Compressor performance and duty
cycle.
Pump or motor components beyond
service life
Return to Reseller/Authorized Service
agent for inspection and repair
Air Leaks
Tube or hose fitting loose
Tighten tube with audible leak and check
under pressure with soapy water
solution (do not over tighten).
Leak at weld
Receiver (tank) must be replaced
Air leak in safety valve (after air
compressor is reset)
Return to Reseller/Authorized Service
agent for inspection and repair
Restricted air inlet
Dirty air filter
Clean or replace air filter
Low discharge pressure
Prolonged, excessive use of air
Decrease amount of air usage.
Compressor is not large enough for air
requirements
Restriction in air filter
Clean or replace air filter
Tank drain tap open
Close drain tap
Broken inlet valves
Return to Reseller/Authorized Service
agent for inspection and repair
Hole in Hose
Check and replace if needed
Excessive moisture in discharge air
Excessive water in tank
Drain tank
High Humidity
Move to area with less humidity or use an
air filter/water trap
Knocking or rattling
Low oil level
Check oil level and adjust to correct
level
Loose screws or nuts
Check all screws and nuts – tighten as
necessary

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WARRANTY STATEMENT
LIMITED WARRANTY
KEEP YOUR RECEIPT.
Proof of purchase will be required to substantiate any warranty claim.
WHAT IS COVERED:
Powerbuilt warrants to the original retail purchaser in New Zealand that this product is free
of manufacturing defect in material and workmanship and agrees,
at Powerbuilt's direction, to either repair, provide replacement parts for, or replace
(without charge for parts or labor) any product or component with a material defect for a
period of 1 year from the date of purchase, except as limited below. Warranty service and
replacement parts are warranted only for the duration of the warranty on the original
product. All replaced parts or products become the property of Powerbuilt Tools.
Warranty
Powerbuilt's Limited Warranty – 1 Year Residential and 90 Day Commercial.
1-year Residential warranty applies as follow: Parts & Labor for the engine, Frame and
pump.
Warranty Term
“Consumer Use” – residential household use by a retail consumer
“Commercial Use” – all other use – commercial, business, industrial, or rental purpose.
How to Obtain Warranty Service
Please contact the Local Distributor who you purchased the product through Please have
necessary information available – Model Number, Serial Number, Proof of Purchase. They
will contact Powerbuilt Tools and assist you through the warranty process.
WARNING
Repairs to this compressor must be made by a qualified Powerbuilt service agent. Powerbuilt will not be
responsible for any damage or injuries caused by the repair or attempted repair by an unauthorized
person or by abusing this compressor.