stellar labs SHD-60 Safety, Installation, Maintenance, And Operation Download

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Stellar Industries, Inc.

190 State Street

PO Box 169

Garner, IA 50438

800-321-3741

Fax: 641-923-2811

www.stellarindustries.com

Model V480 Compressor

Model SUH-60 Compressor

Model SHD-60 Compressor

Manual Part No. 40984

Last Revision: 03/07/08

Subject to Change without Notification.

Safety, Installation, Maintenance, and Operation

WNER

’

ANUAL

Summary of Contents for SHD-60

Page 1: ...ax 641 923 2811 www stellarindustries com Model V480 Compressor Model SUH 60 Compressor Model SHD 60 Compressor Manual Part No 40984 Last Revision 03 07 08 Subject to Change without Notification 2008 Stellar Industries Inc Safety Installation Maintenance and Operation OWNER S MANUAL ...

Page 2: ...Class 4 Compressor Manual Revisions Date of Revision Description of Revision Section Revised ...

Page 3: ...case Group Straight Shaft 9 Cylinder Group 10 Head Group 11 Head Options 12 Optional Head Unloader 14 Flywheel Options 14 Clutch Options 15 SUH 60 Compressor Assembly 16 SHD 60 Compressor Assembly 17 Hydraulics Electrical 18 SHD 60 Control Kit 18 Typical Hydraulic Circuit for Tandum Two Part Pump with Multiple Components 19 Typical Hydraulic Circuit for Single Stage Pump with Multiple Components 1...

Page 4: ... Introduction components and parts deemed necessary for product improvement or commercial production purposes This right is kept with no requirement or obligation for immediate mandatory updating of this manual This product manual is not intended as a training manual for beginners or unskilled operators This manual offers guidelines for correct and safe usage of the compressor maintenance and trou...

Page 5: ...ntal engagement of the tool can cause serious injury Before performing any maintenance on the compressor place a warning tag on the hydraulic power source or disconnect the hoses from the compressor motor to prevent accidental startup of the compressor Always connect hoses to the compressor before energizing the hydraulic power source Be sure all hose connections are tight both air and hydraulic E...

Page 6: ...ting 12 VDC Solenoid Control Valve All Steel Plumbing W JIC Fittings 165 Sq In 300 BTU Cooler 361 CFM 12 Volt Cooler Fan 6061 Aluminum Manifold Direct Drive Coupling Air Pressure Control Valve SHD 60 Drive System Description Cast Iron Crankcase Casting Heavy Ductile Iron Crankshaft Cast Aluminum Cylinder Head Micro honed Connecting Rods High Temperature Precision Pistons Tapered Roller Bearings St...

Page 7: ... nut on the cable end make the adjustment and retighten the jam nut For electronic operated speed controls adjust speed adjustment screw as needed to set RPM For setting engine RPM through the chassis ECM contact local chassis dealer When the air pressure falls below 120 PSI the 12 volt electric solenoid opens allowing hydraulic oil to flow to the hydraulic drive motor then back to the manifold an...

Page 8: ...systems and the general cleanliness of the equipment Proper fluids according to the specifications are required USE AE SYNTHETIC COMPRESSOR OIL P N C0087 COMPRESSOR CRANKCASE CAPACITY IS 1 QUART Service Intervals Maintenance operation Daily Weekly Monthly Hourly Drain air tanks Check crankcase oil level Check fittings and airlines Check hydraulic fluid level Inspect and clean air intake filters Cl...

Page 9: ...s in each head to light torque Tighten 4 chamber bolts to 31 Ft lbs torque Tighten 6 head bolts in each head to 31 Ft lbs torque doing the 2 long center bolts first and the 4 short bolts last After five hours of use re torque bolts to 31 Ft lbs Cylinder Assembly Torque Value 20 FT LBS Procedure After assembling cylinder over pistons and setting into place tighten 6 cap screws finger tight In a cri...

Page 10: ...ggle switch in a convenient location and connect the red wire from the compressor to this switch Connect the other switch terminal to a fuse holder and then to a 12 volt power supply A third wire is required from the air compressor switch when connecting the speed control into the system See drawing below Electric speed control An optional electric or electronic speed control must be used to maint...

Page 11: ...etting at 115 psi minimum 120 psi maximum 3 Cycle compressor to verify correct settings 4 For questions about this procedure please contact Stellar Customer Service Kick On Step 2 Pressure Setting Adjustment Screw 115 120 psi Kick Out Step 1 Pressure Setting Adjustment Screw 145 150 psi Note Turning adjustment screws clockwise increases psi settings Turning adjustment screws counterclockwise decre...

Page 12: ...OIL PUMP DRIVE SLEEVE V480 V360 200 1 27 C6271 FRONT PL GASKET 3 1 0 5 X 9 1 0 N I P L L O R 7 1 8 5 9 28 5825 BEARING SEAL V480 1 C 9 2 1 P M U P L I O G N I R P S 0 6 0 0 C 0 1 1163 BEARING CUP LM67010 1 11 C0059 OIL PUMP TRANSFER BUSHING 1 30 5813 CAP SCR 0 31 18X0 75 SH 5 1 0 8 4 V K C E H C L I O K C I T S P I D E L D N A H 6 8 6 2 2 1 3 1 P M U P L I O 0 5 0 0 C 2 1 13 C6275 PORT PLATE 2 3 1...

Page 13: ...E T A L P T R O P 6 2 6 2 2 6 1 4 5 R G H H 5 2 1 X 8 1 1 3 0 R C S P A C 5 8 4 0 7 1 1 C H S 0 0 1 X 8 1 1 3 0 W E R C S 1 3 0 6 8 1 4 C H S 0 0 1 X 8 1 1 3 0 W E R C S 4 3 0 6 9 1 1 3 6 X 9 1 0 N I P L L O R 9 0 2 2 2 0 2 1 G U L P E K A T N I L I O 5 5 0 0 C 1 2 1 0 0 3 X 8 3 E K A T N I L I O E B U T 6 1 4 5 C 2 2 1 N E E R C S R E T L I F E K A T N I L I O 8 5 0 0 C 3 2 1 2 6 0 0 0 5 N N I P ...

Page 14: ... 8 4 V 0 0 2 N O T S I P 7 6 7 5 3 2 0 8 4 V 0 0 2 N I P N O T S I P 7 6 3 6 C 4 5 C6273 SNAP RING PISTON PIN N5000 62 4 6 C6360 CYLINDER V480 FINISHED O S 1 6 K C O L 1 3 0 R E H S A W 2 2 5 0 7 8 C0922 CAP SCR 0 31 18X1 00 HHGR5 6 9 5827 RING OIL V480 200 FLEX DIVIDER 2 10 32931 RING SCRAPER V480 200 H 48638 2 11 32930 RING CPRSN V480 200 BARREL H 38347 2 12 36368 RING OIL V480 200 RING RAIL 4 C...

Page 15: ... 38 16X3 00 SH HEAD BOLT 2 6 D0887 GASKET VALVE PLATE 200 480 7 24103 VALVE PLATE SUB ASM O S 1 8 C0310 GASKET HEAD 143 230 360 480 1 9 C0291 O RING 214 VITON 9009 75 1 HEAD GROUP 2 4 3 1 Y T Q N O I T P I R C S E D T R A P M E T I 1 S O E G R A H C S I D 0 8 4 V D L O F I N A M 6 4 8 0 D 1 1 0 8 4 V K C O C N I A R D 7 9 7 5 2 1 K L B S C D H Q S T P N 5 7 0 G U L P 0 0 0 6 3 4 T L O B K N A T N ...

Page 16: ...Air Cooled Imbedded Filter 3 4 Threaded NPT Discharge with Head Unloader Ports C1631 Aluminum Water Cooled Imbedded Filter 3 4 Threaded NPT Discharge 15195 Cast Iron Air Cooled 3 4 Threaded Intake Port on Top of Head with 3 4 Discharge Port 3897 Cast Iron Air Cooled 3 4 Threaded Inlet 3 4 Threaded NPT Discharge 23039 Cast Iron Air Cooled 3 4 Threaded Inlet 3 4 Threaded NPT Discharge with Head Unlo...

Page 17: ... 6 0220 CAP SCR 0 25 20 X 1 50 HHGR5 5 2 22599 GASKET UNLOADER 1 7 22596 CAP SCR 0 38 16X4 00 SH HEAD BOLT 1 3 22593 PISTON HEAD UNLOADER CPRSR 2 8 C0040 WASHER HD BOLT STL 1 4 22598 O RING 2 116 HEAD UNLOADER CPRSR 4 9 22597 SPRING PLUNGER PIN UNLOADER CPRSR 2 5 22592 COVER HEAD UNLOADER CPRSR 1 10 22594 PIN PLUNGER HEAD UNLOADER CPRSR 2 ...

Page 18: ...14 Class 4 Compressor Owner s Manual Flywheel Options 22997 12 B GROOVE 22838 14 DUAL GROOVE ...

Page 19: ...Drawings 15 Clutch Options C4705 7 DUAL V C4704 6 DUAL V C4723 6 8 GROOVE SERPENTINE 8198 6 8 GROOVE 24V SERPENTINE 5793 6 8 GROOVE 12V SERPENTINE C4775 7 SINGLE V 5774 6 6 GROOVE 12V SERPENTINE C4762 STRAIGHT BORE ...

Page 20: ... E S O H 5 6 6 4 C 8 1 4 0 3 S S 0 0 4 X 5 7 0 E L P P I N 8 7 8 3 2 9 1 S S A R B W O B L E 5 7 0 G T F 6 6 2 1 D 0 1 11 D1264 FTG 0 75 CLOSE RED BRASS NIPPLE 1 12 5480 VALVE CHECK 0 75 STANDARD 1 13 D1267 FTG 75X90 DEG ST EL BRASS 44164 1 14 C4692 FTG 0 75 JIC ML NPT 12CTX 90 DEG EL 1 15 C0863 SWITCH PRES COMPRESSOR 1 16 C5559 FTG ADAPT 1 8ML 1 4FM NPT 1404 2 4 1 1 E L P P I N X E H 5 2 0 G T F ...

Page 21: ...1 19 O D 5019 4 14 B0682 BRKT COOLER MOUNT SHD60 1 45 13529 FILTER AIR SHD60 1 15 0351 CAP SCR 0 38 16X1 00 HHGR5 6 46 0482 CAP SCR 0 25 20 X 3 00 HHGR5 2 16 C1129 COOLER OIL 1 47 0333 NUT 0 25 20 HHGR5 NYLOC 2 17 C6145 FTG 90 DEG 3 48 0340 WASHER 0 25 FLAT 4 18 C3558 MANIFOLD BLOCK SHD60 1 49 D1465 WASHER 0 31 0 178 THICK 1 19 C6379 FTG SWIVEL NUT ELBOW 12 C6X S 1 50 C4570 CAP SCR 0 31 24X0 75 HH...

Page 22: ...18 Class 4 Compressor Owner s Manual Hydraulics Electrical SHD 60 Control Kit FAN GND CPRSR SPD CTRL PRESSURE SWITCH LINE MOTOR HYDRAULIC MANIFOLD COMPRESSOR 12V INPUT GROUND SPEED CONTROL C B A C B A ...

Page 23: ...Hydraulics Electrical 19 PN 30533 PN 30532 Typical Hydraulic Circuit for Single Stage Pump with Multiple Components Typical Hydraulic Circuit for Tandum Two Part Pump with Multiple Components ...

Page 24: ...4 Compressor Owner s Manual COMPRESSOR RETURN PRESSURE AUXILIARY COOLER SINGLE HYDRAULIC PUMP SUCTION PORT FILTER FILTER SCREEN HYDRAULIC RESERVOIR Typical Hydraulic Circuit for Compressor with Auxiliary Cooler ...

Page 25: ...1 Bearing Oil Seal 1 Oil 1 Qt Filter 1 Ring Set Complete P N C6365 Gasket Set Complete P N C6363 Valve Plate Assembly P N D1489 Consisting of Valve Plate 1 Top Head Gasket 1 Bottom Head Gasket 1 Crankshaft With Bearings Tapered Shaft P N 23874 Straight Shaft P N 23873 Call 800 321 3741 to Order Canister Filter P N 22867 ...

Page 26: ...et Piston rings worn or broken Oil level in crankcase too high Hole in piston Air lock in oil pump No oil in crankcase Pump suction blocked Solution Check fittings on hydraulic motor Inspect clean or replace valves Clean filter assembly Level Add oil if needed Disassemble clean and re install Check Fuse Drain and activate pressure switch Connect lines Locate and remove restriction Relieve air pres...

Page 27: ...pressure switch If there is no power going to the line side of the pressure switch trace the wire back to the power source If there is no power going to the solenoid valve replace the pressure switch Reinstall hydraulic lines Locate and remove restriction Disassemble clean and reinstall or replace If there is power going to the pressure switch press down on the solenoid valve bypass button If the ...

Page 28: ...ower supply and readjust Tighten any hose fitting leaking Reservoir too small Add cooler to system Readjust relief valve Replace with new motor Check and reset flow Inspect clean or replace valves If the hydraulic pump pressure is below the recommended GPM to the hydraulic motor the hydraulic pump could be weak and needs to be replaced If the hydraulic pump is supplying the recommended GPM to the ...

Page 29: ...el too high Piston rings worn or broken Oil level in crankcase too high Blown head gasket Piston rings worn or broken Hole in piston Air pressure switch set incorrectly Leaking air hoses or fittings Inspect and clean filter Tighten bolts to required torque If air back flows from air filter reed valve is faulty and needs to be replaced Inspect and tighten loose hoses Check air demand for items usin...

Page 30: ...be voided if someone other than an authorized American Eagle dealer provides other than routine maintenance service without prior written approval from American Eagle In the case repair work is performed on a American Eagle manufactured product original American Eagle parts must be used to keep the warranty in force The warranty may also be voided if the product is modified or altered in any way n...

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