Service and Maintenance User Manual Auto Crane AC40 Piston Hydraulic Air Compressor This manual must be read carefully before using your Auto Crane Air Compressor. Store in a safe and convenient location for future reference. For technical support: Phone: (918) 836-0463 Fax: (918) 834-5979 http://www.autocrane.
755501900
Contents Revision List....................................................................................................5 Welcome.......................................................................................................6 Safety Information............................................................................................7 Warnings, safety rules, and hazards...........................................................7 Specifications......................................................
Drawings.....................................................................................................25 Frame System...............................................................................26 Piston System.......................................................................................28 Piston Assembly.....................................................................................30 Cooler System.................................................................................
Revision List D ATE LOCATION D ESCPR IPTION OF CHAN GE 5 IN ITIALS 755501900
Welcome General Information Thank you for choosing the Auto Crane AC40 Hydraulic Air Compressor. Before operating this compressor, read over this manual and become well acquainted with your new machine. Doing this will increase your safety and maximize the life of the machine. While this manual is written to be as accurate as possible, Auto Crane strives to continually improve the efficiency and performance of its machines.
Safety IMPORTANT READ BEFORE OPERATING EQUIPMENT Remember, safety is basically common sense. While there are standard safety rules, each situation has its own peculiarities that cannot always be covered by rules. Therefore with your experience and common sense, you are in a position to ensure your and others safety. Lack of attention to safety can result in: accidents, personal injury, reduction in efficiency and worst of all – Loss of Life. Watch for safety hazards and correct them promptly.
Safety The following safety precautions are a general guide to safe operation of the equipment. Read and understand the operations manual and all other safety instructions before using this equipment. Failure to follow operating instructions and/or failure to follow maintenance procedures and intervals could result in personal injury, death, and/or damage to equipment and property. Pressurized System.
Safety Never disable, override, or remove safeties, either temporarily or permanently. Connect air hoses only in full compliance with OSHA Standard 29 CFR 1926:302 (b)(7). The required safety devices (velocity fuses) should be tested in accordance with their manufacturer’s recommendations to verify that they reduce pressure in case of hose failure and will not nuisance trip with the hose and tool combinations in use.
Specifications POWER SOUR CE HYDRAULIC MO TO R OPER ATIN G SPEED CYLIN D ER CON FIG. V4 Piston OIL CAPACITY 1 1/3 Q TS D IM EN SION S 28 1/2"L x 17"H x 20 7/8"W WEIGHT 180 LBS. D ELIVERY @ 100 PSI 40 C F M HYD R AULIC R ESERVOIR R EQ. * 20 GALLO N MIN IMUM COOLIN G AIR N OR M AL GPM @ 1650 R PM 12.18 GPM FAN D IAM ETER 14 1/8" N OR M AL OPER ATIN G PSI 1450 PSI M AXIM UM PSI 2 10 0 P S I 1650 RPM MAX. * Hydraulic reservoir requirement for compressor only.
Description of Components Compressor Assembly - The Auto Crane AC40 hydraulic drive piston compressor assembly is a positive displacement, intermittent-flow, reciprocating unit. The piston compressor consists of a crankshaft, oil filter, oil pump, four connecting rods, pistons, cylinders, and valve assemblies. As the crankshaft rotates, the pistons move up and down. As they move down, a vacuum is created above the piston which allows the reed valve to open and fill the area above the piston with air.
Installation & Operation This air compressor should be installed only by those who have been trained and delegated to do so and who have read and understand the manual. Failure to follow the instructions, procedures, and safety precautions in this manual may result in accidents and injuries. Install, use, and operate this air compressor only in full compliance with all pertinent O.S.H.A., Federal, State, and Local codes or requirements in addition to Auto Crane and any company’s regulations.
Installation & Operation 2. Installing the Wiring This unit is shipped from the factory with all necessary internal wiring installed. The only remaining wiring necessary is the wiring needed to interface your vehicle/power source with the Auto Crane compressor. The unit is shipped with a 4 pin connector, they need to be connected as follows: 1. Pin “A” and Pin “D” are to be connected directly to battery positive (Pin “A”) and battery negative (Pin “D”). 2.
Installation & Operation A compressor service valve should be located at the hose reel inlet or the customer’s air connection port when a hose reel is not used. Typical plumbing from the machine’s air outlet port occurs in the following order: 1. Air tank 2. OSHA valve. 3. Service valve. 4. Moisture trap/gauge/oiler combination (when used). 5. Hose reel (when used). 5. Pre-Start-up Inspection Checks This inspection should be done prior the compressor test. I.
Installation & Operation V. Record all serial numbers for this installation. A. Vehicle V.I.N. ___________________________________________________________________________ B. Hydraulic Pump Data ___________________________________________________________________________ C. Compressor Serial Number ___________________________________________________________________________ D. Auto Crane Serial Number ___________________________________________________________________________ E.
Installation & Operation 6. Operating Procedure I. Read the operation section in the manual carefully before proceeding onto the initial start-up. II. Start power source and allow for warm-up. III. Verify the compressor is disengaged. IV. Engage hydraulic system per company policy. V. Engage compressor. 7. Shutdown Procedure I. Disengage compressor circuit. II. Relieve system of stored air. Operating Conditions The following conditions should exist for maximum performance of the compressor.
Maintenance This section contains instructions for performing the inspection, lubrication, and maintenance procedures required to maintain the compressor in proper operating condition. The importance of performing the maintenance described herein cannot be over emphasized. The periodic maintenance procedures to be performed on the equipment covered by this manual are listed on the following page. It should be understood that the intervals between inspections specified are maximum interval.
Maintenance The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressor package. The items are listed according to their frequency of maintenance, followed by those items which need only “As Required” maintenance. Lubrication and Maintenance Chart SERVICE INTERVAL M AINTENANCE OPERATION DAILY 1. Check crankcase oil level. Add if needed. 2. Drain condensation from air receiver. WEEKLY 1. Inspect the air intake. 2. Check the cylinder head stud torque (see NOTE 2). 3.
Maintenance Lubrication Recommendations It is important that the compressor oil be of a recommended type and that this oil as well as the air filter element be inspected and replaced as started in this manual. The following are general characteristics for a piston lubricant.
Maintenance Due to environmental factors, the useful life of all “extended life” lubricants may be shorter than quoted by the lubricant supplier. Auto Crane encourages the user to closely monitor the lubricant condition and to participate in an oil analysis program with the supplier. No lubricant, however good and/or expensive, can replace proper maintenance and attention. Select and use it wisely.
Maintenance HYDRAULIC OIL COOLER The interior of the oil cooler should be cleaned when the pressure drop across it at full flow exceeds 25 PSI. 1. Remove cooler. 2. Circulate a suitable solvent to dissolve and remove varnish and sludge. 3. Flush generously with hydraulic oil. 4. Once the cooler is reinstalled, fill the hydraulic system with the proper fluid to their appropriate levels.
Troubleshooting The troubleshooting procedures to be performed on the equipment are listed below. Each symptom of trouble for a component or system is followed by a list of probable causes of the trouble and suggested procedures to be followed to identify the cause. In general, the procedures listed should be performed in the order in which they are listed, although the order may be varied if the need is indicated by conditions under which the trouble occurred.
Troubleshooting Contacting Auto Crane Phone: (918) 836-0463 Fax: (918) 834-5979 http://www.autocrane.com When calling for technical support, have the following information available: Machine Serial Number Description of the problem How To Find Specific Machine Information The machine serial number can be found on the Auto Crane serial tag located on the side of machine.
755501900
PARTS AND ILLUSTRATION SECTION 25 755501900
Frame System Reference Drawing - 755501100 8 4 6 7 3 5 1 8 7 2 26 755501900
Frame System Reference Drawing - 755501100 ITEM QTY 1 2 3 4 5 6 7 8 1 6 1 1 1 1 2 2 Parts List PART NUMBER 755501101 755500037 320976000 330371000 755501104 755501105 755501106 755501107 27 DESCRIPTION FRAME NUT WASHER BOLT CLAMP WASHER CLIP RIVET 755501900
Piston System Reference Drawing - 755501200 4 9 6 7 5 8 9 19 18 2 1 14 17 16 10 11 3 6 7 12 5 4 20 3 15 11 13 28 755501900
Piston System Reference Drawing - 755501200 ITEM QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 4 1 2 1 4 4 4 1 2 1 2 1 1/2 ft 1 1 1 1 1 1 1 1 Parts List PART NUMBER 755501201 755501202 755501203 755501204 320976000 366159000 755501105 755501205 755501206 755501207 755501208 755501209 755501210 755501211 755501212 755501213 755501214 755501215 755501216 755501217 DESCRIPTION PLUG SIGHTGLASS PLUG PISTON WASHER BOLT WASHER CAP ELBOW CAP FITTING HOSE ELBOW BRACKET CAP ELEMENT ADAPTER TEE BUSHIN
Piston Assembly Reference Drawing - 755501300 29 37 30 34 44 42 33 3 3 2 40 44 4 1 13 25 43 36 4 1 39 28 22 32 27 35 13 8 11 5 46 14 12 47 19 6 19 23 24 17 16 31 19 38 45 26 41 20 15 7 9 21 18 18 10 28 30 755501900
Piston Assembly Reference Drawing - 755501300 ITEM QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 4 4 8 4 1 1 1 1 1 1 1 1 17 5 1 1 1 2 3 1 1 1 1 1 12 1 2 9 12 12 1 1 2 2 1 2 12 1 1 2 1 2 2 4 1 1 2 Parts List PART NUMBER 755501301 755501302 755501303 755501304 755501305 755501306 755501307 755501308 755501309 755501310 755501311 755501312 007400000 020600000 755501313 755501314 755501315 755501316 755501317 75550131
Cooler System Reference Drawing - 755501400 7 15 8 10 9 4 3 1 7 12 4 13 3 14 1 16 1 5 2 6 11 17 32 755501900
Cooler System Reference Drawing - 755501400 ITEM QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 6 2 4 4 1 4 2 8 7 1 1 1 2 2 1 1 1 Parts List PART NUMBER 020300000 016300000 020200000 005500000 755501401 755501402 755501403 755500061 755501404 755501405 755501406 755501407 755500039 015800000 755501408 755501409 755501410 DESCRIPTION WASHER NUT WASHER BOLT FAN ASSY RIVET ELBOW NUT BOLT SHROUD ELBOW BRACKET RELAY NUT COOLER BLOCK CONNECTOR 33 755501900
Hydraulic Drive System Reference Drawing - 755501500 9 5 6 4 3 8 2 11 12 13 10 1 7 34 755501900
Hydraulic Drive System Reference Drawing - 755501500 ITEM QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 1 1 1 1 1 1 1 2 5 5 5 Parts List PART NUMBER 008702000 755500010 755500057 755501501 755501502 755901000 755501503 755501504 755501505 755501105 020300000 020200000 005604000 DESCRIPTION BOLT MOTOR DECAL HUB HUB SPIDER ELBOW CONNECTOR ADAPTER WASHER WASHER WASHER BOLT 35 755501900
Discharge System Reference Drawing - 755501600 14 8 12 7 11 10 1 9 4 6 14 13 3 12 2 5 11 10 36 755501900
Discharge System Reference Drawing - 755501600 ITEM QTY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 1 1 1 1 1 1 1 1 2 2 2 1 2 Parts List PART NUMBER DESCRIPTION 755501324 755501601 755501602 755501403 755501603 755501604 755501605 755501606 755501607 020300000 020200000 755501608 755501609 755501610 PLUG CONNECTOR NIPPLE ELBOW ADAPTER BLOCK CAP SWITCH SWITCH WASHER WASHER BOLT ELBOW RIVET 37 755501900
Canopy System Reference Drawing - 755501700 4 7 5 1 8 6 9 2 7 3 38 755501900
Canopy System Reference Drawing - 755501700 ITEM QTY 1 2 3 4 5 6 7 8 9 6 6 6 1 1 1 6 1 1 Parts List PART NUMBER 755501701 755501702 755501703 755501704 755921000 755501705 755501107 755501706 755501707 DESCRIPTION BOLT WASHER WASHER CANOPY ASSY LATCH PANEL RIVET HINGE SPACER 39 755501900
Decal System Reference Drawing - 755501800 3E 3A 3G 3H 3D 2 3H 4A 3B 3C 3F 1 3D 40 755501900
Decal System Reference Drawing - 755501800 Parts List ITEM QTY 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 4 4A 2 1 1 1 1 1 1 1 1 1 2 1 1 PART NUMBER 755500053 755501801 755501802 755501803 DESCRIPTION DECAL, AUTO CRANE DECAL, SERIAL TAG AUTOCRANE DECAL, 36 BHP SHEET DECAL, DRIVE COUPLING DECAL, DANGER BREATHING DECAL, WARNING CONNECT AIR DECAL, HYD PRESS & TANK DECAL, WARNING FAN GUARD DECAL, AIR LEXAN DECAL, OIL DRAIN DECAL, COMPR SIGHT GLASS KIT, AC40 DECAL SHEET DECAL, WARNING READ MANUAL 41 755501900
755501900 System Schematic
WARRANTY SECTION 43 755501900
P.O. Box 580697 * Tulsa, OK 74158-0697 4707 N. Mingo Rd. * Phone (918) 836-0463 LIMITED WARRANTY 2 YEAR PARTS AND LABOR Auto Crane will warranty to the consumer for a period of (2) years parts and labor from the date of purchase. Each new Auto Crane unit they sell will be free under normal use and service from defects in material and workmanship. Date of purchase will be honored as the date indicated on the Bill of Sale, which must accompany the Warranty Registration and be on file with Auto Crane.
