Stark 65027 Original instruction manual

5HP TWIN CYLINDER COMPRESSOR PUMP
SAVE THIS MANUAL: KEEP THIS MANUAL FOR SAFETY WARNINGS, PRECAUTIONS, ASSEMBLY,
OPERATING, INSPECTION, MAINTENANCE AND CLEANING PROCEDURES. WRITE THE PRODUCT’S
SERIAL NUMBER ON THE BACK OF THE MANUAL NEAR THE ASSEMBLY DIAGRAM (OR MONTH
AND YEAR OF PURCHASE IF PRODUCT HAS NO NUMBER).
OWNER’S MANUAL AND SAFETY INSTRUCTIONS
ITEM: 65027
FOR QUESTIONS PLEASE CALL OUR CUSTOMER SUPPORT: [phone] MON-FRI 9AM TO 3PM PST

IMPORTANT SAFETY INFORMATION
1
GENERAL SAFETY WARNINGS
Read all safety warnings and instructions. Failure to follow the warnings and instructions may
result in electric shock, fire and/or serious injury. Save all warnings and instructions for future
reference.
SAFETY
The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible
conditions and situations that may occur. It must be understood by the operator that common sense and
caution are factors which cannot be built into this product, but must be supplied by the operator. Read
carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to
follow the safety rules and other basic safety precautions may result in serious personal injury.
Keep work area clean and well lit. Cluttered or dark areas invite accidents.
DO NOT operate the Compressor Pump in explosive atmospheres, such as in the presence of flammable
liquids, gases or dust. Compressor pump motors produce sparks which may ignite the dust or
Keep children and bystanders away from an operating compressor pump.
Stay alert, watch what you are doing and use common sense when operating this compressor pump. DO
NOT use this compressor pump while you are tired or under the influence of drugs, alcohol or medication.
A moment of inattention while operating a compressor pump may result in serious personal injury.
Use personal protective equipment. Always wear ANSI-approved eye protection during setup and use.
Disconnect the plug of the compressor motor from the power source before installing, making any
adjustments, changing accessories, or storing the Compressor Pump. Such preventive safety measures
reduce the risk of starting the unit accidentally.
Store an idle compressor pump out of the reach of children and do not allow persons unfamiliar with the
compressor pump or these instructions to operate it. A compressor pump is dangerous in the hands of
untrained users.
Maintain the Compressor Pump. Keep the Compressor Pump clean for better and safer performance.
Follow instructions for lubricating and changing accessories. Keep dry, clean and free from oil and grease.
Check for misalignment or binding of moving parts, breakage of parts and any other condition that may
affect the compressor’s operation. If damaged, have the compressor repaired before use. Many accidents
are caused by a poorly maintained compressor pump.
Store an idle compressor pump out of the reach of children and do not allow persons unfamiliar with the
compressor pump or these instructions to operate it. A compressor pump is dangerous in the hands of
untrained users.
Use the Compressor Pump in accordance with these instructions, taking into account the working conditions
and the work to be performed. Use of the Compressor Pump for operations different from those intended
could result in a hazardous situation.
Have the Compressor Pump serviced by a qualified repair person using only identical replacement parts.
This will ensure that the safety of the Compressor Pump is maintained.
ONLY a qualified engineer with appropriate certifications may attempt designing a new compressor to
ensure that all required safety and control elements are in place and will work together properly and
safely. This compressor pump is intended ONLY as a replacement for a similarly rated pump on an
existing compressor that includes all other needed components. Constructing a new compressor using
this pump is not covered by this manual.

IMPORTANT SAFETY INFORMATION
2
Use Safety Guard for Pulleys. The Air Compressor Pump Pulley (58), V-belts (not included), and motor
pulley (not included) must be covered by a safety guard (not included) covering all moving elements before
operation.
Before first and every use, verify Pump has sufficient oil.
The use of accessories or attachments not recommended by the manufacturer may result in a risk of
injury to persons.
Misalignment between Motor and Pump can damage the Pump Pulley. Use a straight edge, such as a
yardstick, to check and adjust alignment as needed.
Use proper size motor and motor pulley. This Air Compressor Pump must be installed with a 5 HP electric
motor and pulley (both not included) which can turn the Air Compressor Pump Pulley at approximately 1050
rpm.
Install motor, pulley belts and pulley belt cover securely. Be sure to use the proper size bolts to install the
motor (not included). The belts and belt cover (not included) must be strong enough to prevent breaking
and possible injury.
Be sure all equipment is rated to the appropriate capacity of this pump. Make sure that the lowest rated
piece of equipment being used can handle the maximum pressure of the Air Compressor Pump.
Avoid burns. The Cylinders (22), Cylinder Heads (6) and Air Outlet components become very hot during
operation. DO NOT touch.
Industrial applications must follow OSHA guidelines.
Maintain labels and nameplates on the Compressor Pump. These carry important safety information. If
unreadable or missing, contact Stark Tools for a replacement.
This product is not a toy. Keep it out of reach of children
WARNING: The brass components of this product contain lead, a chemical known to the State of California
to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5,
et seq.)
Risk of fire or explosion - do not spray flammable liquid in a confined area or towards a hot surface. Spray
area must be well-ventilated. DO NOT smoke while spraying or spray where spark or flame is present.
Arcing parts - keep compressor at least 20 feet away from explosive vapors, such as when spraying with
a spray gun.
Risk of bursting! DO NOT adjust regulator higher than marked maximum pressure of attachment.
Risk of injury! DO NOTdirect air stream at people or animals.
DO NOT use to supply breathing air.
DO NOT leave compressor unattended for an extended period while plugged in. Unplug compressor after
working.
Keep compressor well-ventilated. DO NOT cover compressor during use.
Drain tank daily and after use. Internal rust causes tank failure and explosion.
Add correct amount of compressor oil before first use and every use. Operating with low or no oil causes
permanent damage and voids warranty.
DO NOT remove the valve cover or adjust internal components.
Compressor head gets hot during operation. DO NOT touch it or allow children nearby during or immediately
following operation.
Release the pressure in the storage tank before moving.
All air line components, including hoses, pipe, connectors, filters, etc., must be rated for a minimum
working pressure of 150 PSI, or 150% of the maximum system pressure, whichever is greater.

3
IMPORTANT SAFETY INFORMATION
The use of accessories or attachments not recommended by the manufacturer may result in a risk of injury
to persons.
USE OF AN EXTENSION CORD IS NOT RECOMMENDED. If you choose to use an extension cord, use
the following guidelines:
Make sure your extension cord is in good condition.
Be sure to use an extension cord which is heavy enough to carry the current your product will draw. An
undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Table A shows
the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next
heavier gauge. The smaller the gauge number, the heavier the cord.
Operate unit on level surface. Check oil level daily and ll to marked level if needed.
People with pacemakers should consult their physician(s) before use. Electromagnetic elds in close
proximity to heart pacemaker could cause pacemaker interference or pacemaker failure.

4
PARTS INFORMATION
1. AIR FILTER ASSEMBLY
2. CYLINDER
3. OIL FILL PLUG
4. OIL SIGHT GLASS
5. OIL DRAIN PLUG
6. CRANKCASE
7. PUMP PULLEY
8. CYLINDER HEAD

ASSEMBLY
5
1. Place a small amount of grease in the slot at the tapered end of the Crankshaft (49) and insert the
Woodruff Key (50) into the slot.
2. Make sure that the center hole and the keyway on the Pump Pulley (58) are clean and free of burrs and
rough edges.
3. Apply a thin layer of grease to the hole and keyway. With the indented side of the Pulley center facing out,
align the keyway with the Woodruff Key and slide the Pump Pulley over the Crankshaft.
4. Slide the Pulley Washer (59) and Spring Washer (60) onto the Bolt (61) and insert the Bolt through Pump
Pulley and thread counterclockwise into the Crankshaft. Tighten using a wrench (not included).
WARNING! Do not force or hammer the Pump Pulley onto the Crankshaft.
NOTE: The Bolt has a left-hand thread. To tighten, turn bolt counterclockwise.

6
INSTALLATION
NOTE: Depending on your level of expertise, you may wish to have a qualified technician perform this
installation.
NOTICE: Avoid damage to the Air Compressor Pump and other equipment. The Compressor Pump
mounting platform should be flat, level, and strong enough to support the combined weight of the Pump,
electric motor or engine, and related hardware and equipment. It must also be capable of withstanding the
vibration and tension of the drive belt.
1. Place the Air Compressor Pump on the mounting surface at the same level as the 5 HP motor used
to drive it. Pump positioning must incorporate easy access to the Oil Drain Plug (36).
2. Use a motor with the appropriate size pulley to achieve the needed Pump RPM. To calculate the motor
and motor pulley needed to power the pump, multiply the Pump Pulley diameter (14.5”) times the pump
working RPM (1050) which equals 15,225, then divide by the motor RPM. This will determine the motor
pulley diameter (in inches) needed to run the unit. For example: To calculate the pulley diameter needed
for a 1725 RPM motor, multiply 14.5 by 1050, then divide by 1725, which equals a motor pulley size of 8.8
inches. Use the pulley size closest to this figure.
3. The Pump Pulley (58) must be in perfect alignment with the motor pulley (not included). Misalignment
between the Motor and the Pump can cause damage to both the motor and the compressor pump. Use a
straight edge, such as a yardstick, to check and adjust alignment as needed.
NOTE: Ensure the Pump Pulley is installed for counterclockwise rotation when facing the pulley side of the
Pump.
4. Verify that the Pump Pulley turns freely where it overhangs the mounting surface.
5. Place two V-groove belts (not included) over the Pump Pulley and the motor pulley.
6. Pull the Compressor Pump until properly aligned, and the belts are tight. Recheck the motor pulley,
V-belts, and Pump Pulley alignment.
7. Use mounting holes in the Compressor Pump base as a template to mark the spots where four holes will
be drilled in the mounting surface.
8. Move the Compressor Pump aside and drill four 3/8” diameter holes in the mounting surface.

INSTALLATION
7
9. Move the Compressor Pump back to its mounting position and secure each corner of the base with a 3/8”
diameter grade 5 or better bolt, washer, lock washer, and nut (all not included).
10. Make final alignment and adjust belt tension with the motor. It may be necessary to loosen the motor
mounting bolts to adjust the motor location. To test the proper tension on the V-belts, press down on the
belts—there should be 1/2” deflection or less at mid span. Tighten all mounting hardware.
11. Connect plumbing hardware (not included) from the 1”–16 UN Air Outlet to the air destination (i.e.,
air pressure tank of the compressor, not included), routing the tubing in the shortest possible path.
12. Depending on the tool which you will be using with this Compressor Pump, you may need to
incorporate additional components, such as an in-line oiler, a filter, or a dryer (all sold separately), as
shown on Figure D on page 9 and Figure E on page 10. Consult your air tool’s manual for needed
accessories.
13. Install a safety guard (not included) that surrounds the motor pulley, V-belts, and Pump Pulley. This
safety guard must cover all sides of the moving belts and pulleys. It should have a clearance of about one
inch from the moving parts. The safety guard must be sturdy enough to prevent injury.
14. To operate, fill the Compressor Pump Crankcase with Air Compressor Oil (sold separately) following
the directions in the next section. Then follow the manufacturer’s operating instructions and safety warnings
applicable to your air compressor.
WARNING! Avoid serious injuries. DO NOT operate this Air Compressor Pump without a safety guard in
place.
CHECKING THE OIL
1. Check the oil level before operation. Fill the Pump Crankcase with SAE 30W, non-detergent, Air Compressor
Oil (sold separately).
IMPORTANT: Running the Air Compressor Pump with no oil or low oil will cause damage to the equipment
and void the warranty.
2. The oil level should be at the center of the FULL level on the oil level sight glass, as shown in Figure C.
Add oil as needed to maintain this level. Do not let the oil level go below the center dot (LOW as shown in
Figure C) and do not overll the oil so that it is above the center dot (OVERFILL as shown in Figure C) on
the sight glass.
3. TO ADD OIL:
A. Remove the Oil Fill Plug.
B. Using a funnel to avoid spills, pour enough oil into the Pump Crankcase to reach
the FULL level in the Oil Sight Glass.
C. Replace the Oil Fill Plug
NOTE: SAE 30W, non-detergent, Air Compressor Oil (sold separately) is recommended for use with this
compressor.
4. Change the compressor oil after the rst hour of use to remove any debris.
CAUTION! TO PREVENT INJURY FROM BURNS: DO NOT add or change the oil while the compressor is
in operation. Allow the compressor to cool before replacing oil.
NOTE: This pump will consume oil during operation, so check oil level before every use.

8
DIGITAL CONTROL INTERFACE
FIGURE D: PORTABLE AIR SUPPLY SETUP

MAINTENANCE
9
TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION: Turn the power switch “OFF” and
unplug the motor from its electrical outlet before performing any inspection, maintenance, or cleaning
procedures.
TO PREVENT SERIOUS INJURY FROM COMPRESSOR FAILURE: DO NOT use damaged equipment. If
abnormal noise or vibration occurs, have the problem corrected before further use.
CLEANING, MAINTENANCE, AND LUBRICATION
1. BEFORE EACH USE, inspect the general condition of the Compressor Pump. Check for:
• Low oil level
• Loose hardware
• Misalignment or binding of moving parts
• Worn, cracked, or damaged belts
• Cracked or broken parts
• Any other condition that may affect its safe operation.
2. AFTER USE, wipe external surfaces of the compressor with a clean cloth.
MAINTENANCE SCHEDULE
NOTE: The environment in which the Compressor Pump is used, and the frequency of use can affect how
often you will need to check the pump components and perform maintenance procedures.
NOTE: To check for air leaks, apply soapy water to joints while the Air Compressor is pressurized. Look for
air bubbles.
NOTE: To clean the compressor pump surface, wipe with a damp cloth, using a mild detergent or mild
solvent.
NOTE: Use SAE 30W, non-detergent, Air Compressor Oil only (sold separately).

OIL MAINTENANCE
10
Check the oil periodically for clarity. Replace oil if it appears milky or if debris is present, or every 6 months,
or 100 hours of runtime, whichever comes rst. In harsh environments such as high heat or high humidity,
you will need to replace the oil more frequently.
CAUTION! TO PREVENT INJURY FROM BURNS: Allow Compressor Pump to cool before changing the
oil.
1. Place a container under the Oil Drain Plug.
2. Remove the Oil Fill Plug to allow air ow into the Pump.
3. Remove the Oil Drain Plug, allowing the oil to drain into the container.
4. When the oil is completely drained from the Pump, replace the Oil Drain Plug.
5. Fill the Pump with new SAE 30W, non-detergent, Air Compressor Oil to the FULL level on the Oil Sight
Glass.
6. Replace and tighten the Oil Fill Plug.
7. Discard the old oil according to local, state and federal regulations.
AIR FILTER MAINTENANCE
Check the Air Filters weekly to see if they need replacement. If working in dirty environments, you may need
to replace the lters more often.
1. Remove the Air Filter Front Covers.
2. Remove the Air Filter Elements.
3. Replace with new Air Filter Elements
4. Replace the Covers.

TROUBLESHOOTING
11

PARTS DIAGRAM
12

PARTS LIST
13

DISCLAIMER
14
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT
HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS
QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR
DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE
UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS,AND NOT BY THE BUYER. THE BUYER
ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL
PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION
OF REPLACEMENT PARTS THERETO.
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only and are not available individually
as replacement parts.
PLEASE READ THE FOLLOWING CAREFULLY
PRODUCT MADE IN CHINA