Rolair MK103 User manual

TORQUE CHART
PUMP NUMBER MK103 MK113 BK119 PV02A PT03A
PART NUMBER 8390874 837426 8390890 8489817 8390908
HEAD BOLTS 26 NM (19
ft/lb)
27 NM (20
ft/lb)
45 NM (33
ft/lb)
23 NM (17
ft/lb)
23 NM (17
ft/lb)
CYLINDER BOLTS 24 NM (18
ft/lb)
24 NM (18
ft/lb)
24 NM (18
ft/lb)
15 NM (11
ft/lb)
15 NM (11
ft/lb)
BEARING CARRIER
BOLTS
8 NM (6
ft/lb)
8 NM (6
ft/lb)
25 NM (19
ft/lb)
15 NM (11
ft/lb)
15 NM (11
ft/lb)
CONNECTING ROD
BOLTS
N/A N/A N/A 23 NM (17
ft/lb)
23 NM (17
ft/lb)
FLYWHEEL BOLT 28 NM (21
ft/lb)
28 NM (21
ft/lb)
28 NM (21
ft/lb)
23 NM (17
ft/lb)
23 NM (17
ft/lb)
TROUBLESHOOTING & SOLUTIONS
Problem Possible cause Corrective Action
Knocking
1. Lack of oil in crankcase 1. Add oil
2. Worn piston pin 2. Replace pin
3. Worn main bearings 3. Replace bearings
4. Worn connecting rod 4. Replace inserts or rod assembly
5. Excessive crankshaft end play 5. Consult dealer
6.
Piston hitting head due to
foreign matter/carbon
deposits.
6. Inspect, repair or replace valves &
pistons
Low
Discharge
Pressure/
Pumps
Slowly
1. Air leaks 1. Check system for air leaks
2. Broken or dirty valves 2. Replace or clean valves and valve
plates
3. Restricted air intake 3. Replace filter element
4. Blown gaskets 4. Replace gaskets
5. Defective gauges 5. Replace gauges
6. Pump too small for application 6. Consult dealer
Excessive Oil
Consumption
1. Restricted or dirty air filter 1. Clean or replace air filter
2. Crankcase is over-filled with
oil 2. Drain oil and refill to proper lever
3. Worn piston rings 3. Consult dealer
Overheating
Pump
1. Poor ventilation 1. Move pump to allow for better
ventilation
2. Dirty cooling surface 2. Clean pump
3. Restricted air intake 3. Replace filter
4. Low oil lever 4. Add non-detergent, single viscosity oil
5. Dirty or defective reed valve 5. Clean valve plate and replace valves
Oil in the
Discharge
Air
1. Worn piston rings 1. Replace piston rings
2. Pump air intake restricted 2. Replace filter
3. Restricted crankcase breather 3. Clean crankcase breather
4. Excessive oil in pump 4. Check gauge and adjust to proper oil
level
5. Wrong oil viscosity 5. Drain and replace with non-detergent,
single viscosity oil
Water in
Crankcase
1. Pump does not run long 1. Consult dealer
2. Pump too large for application 2. Consult dealer
Pump Owner’s Manual
PLEASE! Read All Instructions Carefully
Before Installing Pump

WARNING
COMPRESSOR DISCHARGE AIR MAY CONTAIN
HYDROCARBONS AND OTHER CONTAMINANTS! DO NOT USE
DISCHARGE AIR FOR BREATHING!
Guarantee
Associate Engineering Corporation warrants that pumps purchased from
them will be free of defects in material and workmanship for a period of
twelve months from date of purchase. Misuse or improper maintenance
will unconditionally void any warranty or claims compensation. Defective
pumps must be returned to the factory for proper evaluation.
Unauthorized repairs or claims without prior factory approval may be
denied.
Associate Engineering Corporation shall in no event be liable neither for
any consequential, incidental or special damages nor for the improper
selection of any pump for a particular application.
Definitions – Safety Warnings
Safety symbols are used throughout this manual to alert you to potentially hazardous
situations. The following definitions describe the level of severity for each signal word.
DANGER: Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
WARNING: Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
CAUTION: Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury or damage to the air
compressor.
Associate Engineering Corp > Customer Service
606 South Lake Street > P.O. Box 346 > Hustisford WI 53034-0346
920.349.3281 > Service Fax [phone]
Lubrication: Prior to daily operation, make a habit of checking the oil
level in your compressor pump. A sight gauge on the outside of the
pump’s crankcase is provided to make the job easier. ALWAYS
maintain the oil level to read 2/3 full on the sight gauge. Oil levels over
this amount will result in oil blowing past the rings or through the
crankcase breather. Lower amounts of oil will result in insufficient
lubrication of moving parts.
Reciprocating air compressor pumps will consume a certain amount of oil under normal operation.
If you are concerned about your oil consumption, monitor and record oil consumption daily and
consult you local dealer. When filling your crankcase with oil, be sure to use a single viscosity, non-
detergent oil blended specifically for air compressor use (consult chart below).
DO NOT USE A
DETERGENT OIL!!
IMPORTANT: All models are splash lubricated by means of dippers on the
connecting rods. The pump MUST be operated in a level position for proper lubrication.
TEMPERATURE
Fahrenheit 0°-32°F 32°-55°F 56°-100°F -10°-115°F
Celsius -17°-0°C 0°-13°C 14°-38°C -23°-47°C
Non-Detergent Air
Compressor Oil * 10 WT 20 WT 30 WT Synthetic Oil
*A suitable air compressor oil has additives to reduce wear, eliminate foaming and prevent
carboning.
Maintenance: Regular maintenance insures trouble-free operation. Your new pump represents the
finest engineering and construction available. However, even the finest machinery requires
periodic maintenance. A good maintenance program will add years of service to your air
compressor. The following is recommended as a minimum maintenance program. For your
protection, disconnect power supply after each day’s operation and drain air from system before
performing any maintenance.
Break-In Period: Your new pump does not come filled with oil. By using the chart above, select
the type of oil that best fits your application:
Important: Replace the oil after the first 50 hours (2 weeks) of operation. Re-torque the head
bolts after the first 200 hours (4 weeks) of operation.
MAINTENANCE SCHEDULE
DAILY 1. Check oil level and fill as needed.
EVERY 2 WEEKS OR 100 1. Repeat daily procedure.
HOURS 2. Replace oil after first 50 hours of operation.
3. Check drive belt and adjust if necessary.
4. Retorque pump head bolts (see chart below)
MONTHLY OR 200 HOURS 1. Repeat above procedures.
2. Change compressor oil.
3. Check for air and oil leaks and correct.
4. Tighten all hardware.
ANNUALLY OR 2000 1. Repeat above procedures.
HOURS 2. Check the valves in compressor and replace if damaged or
worn.

PUMP SPECIFICATIONS
MK103 MK113 BK119 PV02A PT03A
Part Number 8390874 8377426 8390890 8489817 8390908
Horsepower Rating
(Electric)
1.5 - 3.0 2.0 - 4.0 5.0
–
7.5 1.5
–
3.0 3.0
–
5.0
Weight (lb.) 18.1 31.1 58.8 44.1 59.6
(kg.) 8.3 14.1 26.5 20.0 27.0
Flywheel O.D. (in.) 9.9 12.0 14.9 11.0 10.7
(mm.) 251.4 305.0 398.0 279.4 271.8
RPM (min.) 900 900 900 800 900
(max.) 1400 1400 1400 1250 1400
Max Pressure (PSI) 145 145 175 145 145
Bore & Stroke (in.) 2.56 x 1.57 2.56 x 2.28 4.13/2.05 x 3.10 2.50 x 2.0 2.50 x 1.875
(mm.) 65.0 x 40.0 65.0 x 58.0 105.0/52.0 x
78.0
63.5 x
50.8
63.5 x 47.6
CFM Free Air (1200
RPM)
8.0 12.0 23.0 10.5 18.0
dB-A 79 78 80 78 79
Oil Capacity
(ounces)
17 30 45 24 24
(liters) .50 .90 1.33 .70 .70
Unpacking Instructions: Check for damaged parts. DO NOT install pump if any parts are damaged
or missing. Parts included with pump: Flywheel, Filter, Dipstick / Breather, Oil Sight Gauge. This
pump is not shipped with oil!
YOU MUST ADD OIL to the pump before operating.
Belts: Install belts on compressor and motor pulleys. Belt tension should be adjusted to allow 3/8”
to 1/2” deflection with normal thumb pressure.
Drive Pulleys: Drive pulleys must be properly aligned and belt drive tension set to specifications.
Improper pulley alignment and belt tension may cause motor overloading, excessive vibration and
premature belt and/or bearing failure. As the compressor starts, check the rotation of the flywheel.
The direction of the rotation must be counter-clockwise when facing the flywheel. Should the
rotation be incorrect, disengage the power supply and check the motor wiring.
SPECIAL NOTE: Pump flywheel bolt has left-handed thread and tapered shaft. Remove nut by
turning clockwise.
To determine the correct motor pulley, use the following formula:
Motor Pulley = Flywheel O.D. x Compressor RPM
Motor RPM
Belt Guards: Belt guards should be designed to achieve the required degree of protections and still
allow full air flow from the compressor sheave across the unit. When the compressor is installed,
make sure the guard side is at least 18” away from a wall to provide adequate cooling of the motor
and pump. IMPORTANT: DO NOT RUN COMPRESSOR WITHOUT BELT GUARD INSTALLED.
SAFETY WARNINGS
READ AND UNDERSTAND ALL SAFETY WARNINGS BEFORE USING AIR COMPRESSOR
Hazard Level Potential Hazard How to Avoid Hazard
Risk of Asphyxiation
Serious injury or death may occur
from inhaling compressed air. The
air stream may contain carbon
monoxide, toxic vapors or solid
particles.
Never inhale compressed air directly from
the pump, receiver, or from a breathing
device connected to the air compressor.
Sprayed materials such as paint,
stucco, insecticides, solvents, etc.,
contain harmful vapors and poisons
that may cause serious injury or
death if inhaled.
Operate compressor only in a well-
ventilated area. Use a respirator device
and follow the manufacturer’s
recommendations for their spray
equipment. Keep compressor at least 25
feet away from spray equipment.
Serious injury or death may occur if
the exhaust from gas-powered
small engines is inhaled. Engine
exhaust fumes contain poisonous,
carbon monoxide which is odorless
and colorless.
Operate gas-powered compressors only
in a well-ventilated area. Avoid inhaling
engine exhaust fumes, and never run a
small gas-powered engine in a closed
building or confined area without
adequate ventilation.
Risk of Bursting
Serious injury or death may occur
from an air tank explosion if the air
tanks are not properly maintained
or if modifications, alterations or
repairs are attempted to the air
receivers.
Drain air tanks daily or after each use.
Never drill into, weld, patch or modify the
air tanks. If a leak develops, replace the
tank immediately or replace the entire
compressor.
Serious injury or death may occur if
modifications are made to the pilot
unloader valve, pressure switch,
safety relief valve or other
components that control the tank
pressure.
Never make adjustments to the
components that control tank pressure.
Do not make alterations to the factory
operating pressure settings. Check
operation of the safety valve on a regular
basis and never operate without a factory
approved safety valve.
Serious injury may occur if
accessories or attachments are
operated above the manufacturer’s
recommended pressure ratings,
causing them to explode or fly
apart.
Do not use air tools or attachments
before reading the owner’s manual to
determine the maximum pressure
recommendations. Never exceed the
manufacturer’s maximum allowable
pressure ratings. Do not use compressor
to inflate small low pressure objects such
as toys.
WARNING
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects or
other reproductive harm.

SAFETY WARNINGS (con’t)
Risk of Electrocution
or Electrical Shock
Serious injury or death could occur
if the air compressor is not properly
grounded.
Always plug compressor into a properly
grounded outlet which provides correct
voltage, proper grounding and adequate
fuse protection.
Electrical shock may occur if
compressor is not properly
operated.
Never operate air compressor in wet
conditions or outdoors when it’s raining.
Do not allow electric cords to lay in
water. Do not operate with damaged
power cord or with protective electrical
covers removed. Do not touch plug with
wet hands. Do not pull on electric cord to
disconnect from the outlet.
Serious injury or death may occur if
electrical repairs are attempted by
unqualified personnel.
Any electrical repairs or wiring performed
on this compressor should only be
performed by authorized service
personnel in accordance with the
National and Local Electric Codes.
Risk of Explosion or
Fire
Serious injury or death may result
from normal electrical sparks that
occur within the motor and/or
pressure switch.
Always operate compressor in a well-
ventilated area free of combustible
materials, gasoline, flammable solvents or
vapors. Always locate compressor at
least 20 feet away from work area if
spraying flammable materials.
Serious injury may occur if a fire is
caused by overheating due to
inadequate ventilation or
restrictions to any of the
compressors ventilation openings.
Never place objects against or on top of
an air compressor. Always operate air
compressor at least 18” away from any
wall or obstruction. Always operate in a
clean, dry and well-ventilated area.
Serious injury or death may occur
from a fire or explosion if spilled
gas or vapors come in contact with
hot engine parts and ignite.
Never attempt to fill the gas tank while
the engine is hot or running. Add fuel
outdoors in a well-ventilated area. Do not
fill gas tank near lit cigarettes or near
other sources of ignition.
Risk from Moving
Parts
Serious injury may occur from
moving parts such as belts, pulleys,
flywheels or fans if they came in
contact with you or your clothing.
Never operate the air compressor without
protective belt guards installed. Replace
damaged protective covers or guards
immediately.
An electric air compressor with
automatic controls can restart at
any time and cause bodily injury
when least expected.
Always unplug air compressor and drain
air tanks completely before attempting
any repairs or performing maintenance.
Never allow children or adolescents to
operate air compressor.
Serious injury may occur if repairs
are attempted with damaged,
missing or removed protective
guards, shrouds or missing covers.
All repairs to the air compressor should
be made only by authorized or trained
service personnel.
Risk of Burn
Serious burn injuries could occur
from touching exposed metal parts
such as the compressor head,
copper/braided discharge lines and
engine exhaust muffler during
operation, and even after
compressor is shut down for
sometime.
Never touch any of the exposed metal
parts during operation and for an
extended period of time after the air
compressor has shut down.
Do not attempt maintenance on the unit
until it has been allowed to completely
cool.
SAFETY WARNINGS (con’t)
Risk of Injury from
Lifting
Serious injury can result from
attempting to lift an object that is
too heavy.
Always obtain assistance from others
before attempting to lift any object that is
too heavy for one person.
Flying Objects
Serious injury may occur from loose
debris being propelled at high
speeds from the compressed air
stream.
Always wear OSHA required “287” safety
glasses to protect the eyes during
operation of the air compressor. Never
point the air stream or tools at any point
of your body, other people or animals.
Always turn off the air compressor and
drain tank pressure completely before
attempting maintenance or attaching air
tools.
Warning
Risk of Unsafe
Operation
Serious injury or death may occur
to you or others if air compressor is
used in an unsafe manner.
Review and understand all instructions
and warnings in your owner’s manual.
Know how to stop the air compressor.
Do not operate until you are thoroughly
familiar with all of the controls. Do not
operate the compressor if fatigued or
under the influence of alcohol or drugs.
Stay alert while operating the compressor
and pay close attention to the task at
hand.
Caution
Risk of Damage to
Air Compressor or
Property
Failure to transport or operate the
air compressor properly may result
in major repair expenses. Oil leaks
will damage carpets, painted
surfaces, flooring and other items.
Check oil levels daily and maintain proper
oil levels. Always run compressor in a
level, secure position that keeps it from
tipping or falling during use. Do not
operate without an air filter or in a
corrosive environment.
Always transport in a level position and
use protective mats to keep truck beds
clean, etc. Check drain bolts regularly
and do not overfill machinery with oil.
Please note that this product may not be equipped with a spark arresting muffler. If the
compressor is operated around flammable materials or agricultural crops, brush, forests, and
grasslands an approved spark arrestor must be installed, maintained and in good working order.
An approved spark arrestor is legally required in the State of California under sections 4442 and
4443 of the California Public Resources Code Statute section 130050.
This product contains chemicals, including lead, known to the state of California to cause cancer,
birth defects, and other reproductive harm. Always wash hands after handling this product.
606 South Lake Street > P.O. Box 346 > Hustisford, WI 53034-0346
920.349.3281 > fax [phone] > www.rolair.com