Model SRS-65 Above Deck Compressor Manual

MODEL SRS-65
ROTARY SCREW COMPRESSOR
OWNERS’ MANUAL
Safety • Operation • Installation • Parts
Models
SRS-65E (PN 53887)
SRS-65P (PN 53889)
Subject to Change without Notification.
© 2014 American Eagle, Inc.
American Eagle, Inc.
740 N. State Street
PO Box 169
Garner, IA 50438
800-392-3015
Fax: 641-923-9099
www.americaneagleacc.com
Last Revision: 12/16/14
SRS-65 Manual Revisions
Table of Contents
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Chapter 1 - Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Decals (From Kit PN 22418) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Chapter 2 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 3 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 4 - Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Condensation Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Changing the Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Minimum Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic Oil Cooler/Compressor Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 5 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SRS-65 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Temperature Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressor Pressure Switch (RP/E Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SRS-65 Compressor Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Typical Hydraulic Circuit for Single Stage Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Typical Hydraulic Circuit for Tandum (Two Part) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Typical Hydraulic Circuit for Compressor with Auxiliary Cooler. . . . . . . . . . . . . . . . . . . . 20
Chapter 6 - Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SRS-65E Compressor Assembly - PN 53887 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SRS-65E Compressor Assembly - PN 53887 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SRS-65P Compressor Assembly - PN 53889 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SRS-65P Compressor Assembly - PN 53889 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 7 - Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 8 - Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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SRS-65 Owner’s Manual
Introduction
American Eagle Compressors are designed
to provide safe and dependable service for
a variety of operations. With proper use and
maintenance, these compressors will
operate at peak performance for many
years.
Please be aware that some sections of this
manual contain information pertaining to
American Eagle manufactured compressors
in general and may or may not apply to
your specific model.
Once you feel comfortable with the material
contained in this manual, strive to exercise
your knowledge as you safely operate and
maintain the compressor. This process is vital
to the proper use of the unit.
In closing:
If more information is required or technical
assistance is needed, or if you feel that any
part of this manual is unclear or incorrect,
please contact the AE Customer Service
Department by phone at 800-321-3741 or
email at [email protected].
To promote this longevity, carefully study the
information contained in this manual before
putting the equipment into service. Though
it is not intended to be a training manual for
beginners, this manual should provide solid
guidelines for the safe and proper usage of
the compressor.
A few notes on this manual:
A copy of this manual is provided with every
compressor and can be found in the hard
plastic manual case that is installed on the
chassis. This manual shall remain with the
compressor at all times.
Information contained within this manual
does not cover all maintenance, operating,
or repair instructions pertinent to all possible
situations.
This manual is not binding. American Eagle,
Inc. reserves the right to change, at any
time, any or all of the items, 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.
ATTENTION
Failure to adhere to the
instructions could result in
property damage or even serious
bodily injury to the operator or
others close to the compressor.
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST
Or email at the following addresses:
Technical Questions, and Information
Order Parts
Warranty Information
[email protected]
[email protected]
[email protected]
Chapter 1 - Safety
Please Read the Following Carefully! This
portion of the manual contains information
regarding all American Eagle manufactured
compressors. Some items contained within
this chapter may not apply to your specific
equipment.
Safety should be the number one thought on
every operator’s mind. Three factors should
exist for safe operation: a qualified operator,
well-maintained equipment, and the proper
use of this equipment. The following
information should be read and understood
completely by everyone working with or near
the compressor before putting the unit into
operation.
Please take note that American Eagle, Inc. is
not liable for accidents incurred by the
compressor because of non-fulfillment from
the operator’s side of current rules, laws, and
regulations.
The SRS-65 Rotary Screw Compressor will
provide safe and dependable service if
operated according to instructions. Read
and understand the safety precautions given
in this manual and on the decals attached to
the shields. Failure to do so can result in
personal injury or equipment damage.
Operators and maintenance personnel must
always comply with the safety precautions.
These precautions are given here for your
safety. Review them carefully before operating the compressor and before performing
maintenance or repairs.
Supervising personnel should develop additional precautions relating to the specific
work area and local safety regulations.
Precautions
Always wear safety equipment such as goggles, ear plugs and head protection at all
times when operating the compressor.
Do not inspect or clean the compressor while
Safety
1
the power source is connected. Accidental
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 power source. Be sure
all hose connections are tight.
Establish a training program for all operators
to ensure safe operation.
Do not operate the compressor unless thoroughly trained or under the supervision of an
instructor.
Do not operate the compressor if it is damaged, improperly adjusted or not completely
or properly assembled.
Never operate the compressor with any of
the guards removed.
Do not attempt to adjust or disable the compressors air pressure relief valve. This valve
protects the compressor in the event of
blockage or air control system malfunction.
The surface of the air compressor and the
plumbing between the compressor and the
cooler may reach temperatures above 150
degrees. Touching these surfaces during
operation can cause burns.
The air taken in by the air compressor must be
free of flammable fumes and vapors.
Compressor speed should not exceed 8000
RPM.
Use and operate this air compressor only in
full compliance with all pertinent O.S.H.A.
requirements and all Federal, State and Local
codes or requirements.
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SRS-65 Owner’s Manual
Safety Decals (From Kit PN 22418)
WARNING
Hot parts can
cause severe
burns.
Do not touch any
internal surfaces
during or shortly
after operation.
WARNING
All hoses should be
connected in full
compliance with
federal state and
local codes and
regulations.
Safety devices should
be tested in
accordance with
manufacturer’s
recommendations.
WARNING
Do not use air from
this compressor for
breathing or for the
processing of
consumables except
in full compliance with
federal, state, and
local codes and
regulations.
WARNING
High pressure
hydraulic system.
Do not attempt to search
for leaks with hand or
other part of the body.
Doing this can cause
subcutaneous injection
or amputation.
WARNING
Do not remove caps,
plugs, or other
components while
the compressor
is running or has
pressure in the tank.
Disconnect power and
relieve all pressure
prior to maintenance.
Paper should be
used to check for
hydraulic leaks.
DANGER
Read the operation
manual prior to use of
this unit.
Failure to adhere to
instructions can result
in personal injury.
Replacement manuals
can be purchased
from:
American Eagle
190 State Street
Garner, Iowa 50438
WARNING
Rotating parts can
cause serious injury.
Keep body parts clear
while unit is in
operation.
Never operate this unit
without cover
completely attached.
Chapter 2 - Specifications
SPECIFICATIONS
SRS-65E
Hydraulic System
18 GPM
Compressor RPM
7500-8000 RPM
System Pressure
2800 PSI
Max Air Pressure*
150 PSI
Relief
3500 PSI
Delivery (At Max Speed)
65 CFM @ 100 PSI
Weight
313 lbs.
Dimensions (Length)
29.00"
Dimensions (Width)
23.00"
Dimensions (Height)
26.00"
Electrical
12 VDC
Crankcase Oil Capacity
5 Quarts
Oil Reservoir Capacity
Minimum: 26 Gallon
Plumbing/Fittings
Steel W/JIC Fittings
Cooler Fan
1710 CFM, 12 Volt
Drive
Belt Drive
Manifold
6061 Aluminum
Control Valve
12 VDC Solenoid
*Max Air Pressure should never exceed 175 PSI.
Specifications
SRS-65P
18 GPM
7500-8000 RPM
2800 PSI
150 PSI
3500 PSI
65 CFM @ 100 PSI
313 lbs.
29.00"
23.00"
26.00"
12 VDC
5 Quarts
Minimum: 26 Gallon
Steel W/JIC Fittings
1710 CFM, 12 Volt
Belt Drive
6061 Aluminum
12 VDC Solenoid
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SRS-65 Owner’s Manual
Chapter 3 - Operation
Operation
5
Each compressor is bench tested under load at the factory to ensure proper operation.
While it is not necessary to follow any break-in procedure, the following checks should be
made before putting the unit into service and periodically during use.
Before Start-Up
Inspect unit for any visible signs of damage.
Check the oil level in the compressor (See Section “Changing the Oil”). If oil is needed,
use American Eagle synthetic compressor oil (P/N C0087) or an equivalent synthetic oil.
Check hoses (air and hydraulic) for weak or worn condition and make sure that all connections are secure.
Check the air intake filter to make certain that it is clean and unobstructed. A dirty air filter
is a possible cause of reduced air output.
General Information
To use the compressor, start the vehicle
engine and engage the hydraulic system.
The compressor can now be activated
using the compressor switch. This energizes
the hydraulic solenoid sending oil to the
hydraulic drive motor and starts the compressor. The system will now function automatically. Once engaged, adjust the
engine speed control to ensure that the
compressor speed does not exceed 8000
Rpm under load. Adjustment instructions are
provided with the speed control unit.
Air Operations(SRS-65RP & SRS-65E)
Activating the compressor switch sends
power to the cooling fan, hydraulic solenoid
valve and normally closed terminal (87A)
on the Bosch relay. The normally open
hydraulic solenoid valve closes, sending
hydraulic oil to the motor operating the
compressor. The fan and compressor operate whenever the hydraulic system is
engaged and the compressor switch is on.
Power from the common terminal (30) on
the Bosch relay goes to the line terminals on
the compressor pressure switch. If the air
pressure is below the kick out pressure (115
psi minimum/120 psi maximum) the pressure
switch closes sending power to the engine
speed control and compressor air inlet solenoid valve. The engine speeds up and the
compressor begins pumping air. When the
air pressure reaches the kick out pressure
setting (145 psi minimum/150 psi maximum)
the pressure switch opens, shutting the air
inlet valve and deactivating the speed
control.
The compressor is protected by an air pressure and compressor oil switch gauge. The
coil on the Bosch relay is grounded through
these two switch gauges. If the air pressure
or compressor oil temperature exceeds the
switch gauge settings they close, completing the circuit and energizing the relay coil.
The normally closed switch on the Bosch
relay opens cutting power to the compressor pressure switch. The compressor stops
pumping air and the engine slows down.
The switch gauges are set at the factory
and should not be adjusted.
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SRS-65 Owner’s Manual
Air Operations (SRS-65P)
Activating the compressor switch sends
power to the cooling fan and normally
closed terminal (87A) of the Bosch relay.
Power from the Bosch relay goes to the
hydraulic solenoid valve and speed control.
The compressor and speed control are activated any time the hydraulic system is
engaged and the compressor switch is on.
The compressor pumps air until the pressure
reaches 175 psi. The proportional compressor inlet valve then shuts down and only
allows in sufficient air to maintain 175 psi.
This pressure will be maintained as long as
the air usage remains within the capacity of
the compressor. The inlet valve is controlled
by the compressors pneumatic control circuit. The air pressure is factory set and
needs no further adjustment. The pneumatically controlled compressor is also protected by two switch gauges. If the air pressure
or oil temperature exceeds the preset values, the switch closes energizing the relay
coil which opens the normally closed switch
on the relay shutting off power to the
hydraulic solenoid and speed control.
Operating Notes:
This rotary screw compressor must not be
used for breathing air. To do so will cause
serious injury whether air is supplied direct
from the compressor source or to breathing
tanks for later use. Any and all liabilities for
damage or loss due to injuries, death
and/or property damage, including consequential damages stemming from the use
of this compressor to supply breathing air
will be disclaimed by the manufacturer.
The use of this compressor as a booster
pump and/or to compress a medium other
than atmospheric air is strictly nonapproved and can result in equipment
damage and/or injury. Non-approved uses
will also void the warranty.
Never use plastic pipe or improperly rated
metal pipe. Improper piping materials can
burst and cause injury or property damage.
Maintenance
Chapter 4 - Maintenance
The following table is a list of routine maintenance items, including service intervals. Service
intervals are listed as hours, days, or weeks, whichever occurs first. American Eagle recommends that these service intervals be followed. Before performing any maintenance function, turn off compressor, hydraulic system, truck engine and remove keys to assure that
compressor is not started. Be sure all air pressure in unit is relieved. Failure to do so may
result in injury or equipment damage.
Service Intervals
Maintenance Schedule
Daily
Weekly
Monthly
Hourly
Drain air tanks.
Check compressor case oil level.
Check fittings and airlines.
Check hydraulic fluid level.
Inspect and clean air intake filters.
100
Check oil cooler. Clean as needed.
Replace coalescering/separator cartridge.
12
3000
Change compressor oil and oil filter.
6
1000
Replace hydraulic filter.
6
Replace air filter.
3
Tighten all fittings and fasteners.
3
Check all electrical connections.
3
100
General preventative maintenance includes maintaining proper fluid level in both 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 5 QUARTS.
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SRS-65 Owner’s Manual
Oil Level
The oil level in the compressor case is an important factor for the operational reliability of
the system.
Check Intervals:
1. Before starting unit.
2. Every 100 operating hours
Check Procedures:
1. Turn off the compressor, hydraulic system and
truck engine to ensure that compressor is not started.
2. Wait for one full minute.
3. Slowly unscrew the oil fill cap on the compressor
case (also referred to as the separator receiver).
4. Check the oil level.
5. If the oil level is under the minimum level, add oil to maximum level as shown.
6. Replace cap and hand tighten. Unit is ready to be put into service.
MAX
MIN
Note: The screw-type oil fill cap is has a bleed hole which will release pressure in the compressor case. The bleed hole is exposed after the cap is loosened about two turns. If there
is still pressure in the case, wait a few minutes for it to bleed off.
Condensation Drain
Condensation (water) in the oil affects the operation and life of the screw compressor.
Screw compressors are especially vulnerable due to the fact that the oil is used for both
sealing and lubrication. Both oil and water are removed from the air in the separator cartridge and returned to the compressor case. Condensation builds up faster when the compressor is operated intermittently in humid conditions. Under these conditions, the condensate should be drained each day before start up when the compressor is cold.
Possible Malfunctions:
Insufficient lubrication.
Poor air/oil separation and high pressure across the separator cartridge.
Corrosion and rust formation.
Maintenance Procedure
1. Unscrew oil fill cap.
2. Place a container under the oil drain pipe and carefully unscrew the oil drain cap.
3. Drain the water from the compressor case until nothing but oil comes out, replace the
cap and tighten.
4. Fill the compressor case with oil to maximum and replace oil fill cap.
5. Turn on compressor and operate for three minutes.
6. Check oil level and fill if low.
7. Dispose of condensate (mixture on water and oil) in accordance with local and federal
regulations.
Maintenance
Changing the Oil
WARNING: COMPRESSOR MUST BE STOPPED AND ALL AIR RECEIVERS DISCHARGED BEFORE
CHANGING OIL. COMPRESSOR OIL IS HOT, ABOVE 175 DEGREES F (80 DEGREES C) AND
CAN CAUSE BURNS.
Note: Change the oil with the compressor at operating temperature of 140-175 degrees F
(60-80 degrees C).
1. Turn off the compressor, hydraulic system
and truck engine to ensure that compressor is not started.
2. Discharge air receiver.
3. Wait for one full minute.
4. Slowly unscrew the oil fill cap on the compressor case.
5. Place a container under the oil drain pipe
and carefully unscrew the oil drain cap.
6. Drain the oil from the compressor case,
then replace and tighten oil drain cap.
7. Refill with oil to maximum level and replace
oil fill cap. Oil capacity is 4 quarts.
8. Operate compressor for 3 minutes.
9. Check oil and fill to maximum if necessary.
Oil Recommendation
Screw compressors must be operated using the
most suitable oil for operation. The compressor manufacturer must approve this oil for use. The oil must
also be suitable for use in unfavorable conditions
such as: contamination of the intake air by gases,
solvent vapors, exhaust gases, and high ambient
temperature conditions.
Suitable types and brands of oil may be specified
on request. Suitable screw compressor oils can be
mineral oils, synthetic oils, and biological degradable oils.
The substances and materials used in the compressor such as seals must be taken into account when
selecting the types of oil. Corrosion or other material
degradation must not occur.
Important: Do not mix different types of oil.
Important: In the case of ambient temperatures
close to freezing, prevent the unit from freezing.
Pipeline Materials:
The oil used in screw compressors can degrade
plastics used in air pipelines.
OIL FILL
OIL DRAIN
Oil Requirements
High aging stability
High disperse capacity
Low emulsification tendency
Flash point: above 400°F/ 200°C
Pour-point: 5° below lowest ambient temperature
minimum
Minimum foaming
High corrosion protection
Hydraulic or turbine oil
Basic oil: solvate
Operating temperature: up to 230°F / 110°C
Viscosity class: ISO 46 or ISO VG 68
Viscosity at 104°F / 40°C: ca. 42-50 mm2/s (cST)
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SRS-65 Owner’s Manual
Oil Filter
The oil filter is located to the front of the unit. When viewing the unit from the oil fill cap end, the oil filter will
be to the left front. It is necessary to remove the side panel to access the oil filter. Replace the filter after the
first 50 hours of service and every 1,000 hours thereafter.
Maintenance Procedure
1. Turn off the compressor, hydraulic system and truck engine to ensure
that compressor is not started.
2. Slowly unscrew and remove the oil filter with an oil filter wrench.
3. Grease the new filter gasket.
4. Before installing, hold the new filter upright and fill it with the same oil as
used in the compressor case.
5. Screw the new filter onto the compressor. Hand tighten, do not use a
filter wrench. Turn approximately 3/4 turn after gasket contacts the
compressor.
6. Run compressor for 3 minutes.
7. Check oil level and fill if necessary.
OIL FILTER
P/N 15323
Separator Cartridge
The separator cartridge is disposable and is located on top of the filter support.
The cartridge has to be replaced at least once per year and at a maximum of 3000 operating hours. If
intake air is often contaminated or the oil quality is poor, the cartridge will tend to clog earlier and will need
to be changed more often.
Maintenance Procedure:
1. Turn off the compressor, hydraulic system and truck engine to ensure
that compressor is not started.
2. Slowly unscrew and remove cartridge with an oil filter wrench.
3. Screw the new cartridge onto the filter support. Hand tighten, do not
use a filter wrench. Turn approximately 3/4 turn after gasket contacts
the compressor.
4 Write the date of change and operating hours on cartridge.
5. Run compressor for 3 minutes.
6. Check cartridge to ensure that it is tight.
SEPARATOR
CARTRIDGE
P/N 15324
Intake Filter
The air intake filter should be changed every 100 hours of operation. The filter may require changing or
cleaning more frequently if the compressor is operated in a dusty environment.
Maintenance Procedure:
1. Turn off the compressor, hydraulic system and truck
engine to ensure that compressor is not started.
2. Open filter lid and carefully remove filter.
3. Carefully remove dust from the intake housing.
4. Clean and install or install new filter.
•Clean filter be tapping outside of filter on a hard
surface.
•Clean filter with compressed air by blowing from the
inside to the outside. Limit air pressure to 75 psi.
5. Close filter lid.
6. Test run compressor.
ATTENTION: ANY DIRT OR DEBRIS THAT ENTERS THE
COMPRESSOR INTAKE WHEN THE AIR FILTER IS REMOVED
CAN CAUSE IRREVERSIBLE DAMAGE.
AIR FILTER
P/N 15322
Belt Tension
NEW BELT
Installation Tension: 98.0 lbf
Tensioning Force: 6.8 lbf
Belt Deflection: 9/64 in
Span Length: 9.00 in
USED BELT
Installation Tension: 65.4 lbf
Tensioning Force: 4.8 lbf
Belt Deflection: 9/64 in
Span Length: 9.00 in
Maintenance
Belt Deflection
Force Applied
Minimum Pressure Valve
Span
The minimum pressure valve is set at the factory. If oil blows out through the air filter the
minimum pressure valve may need to be set.
Minimum Pressure Valve Set Procedure
1. Remove the lock nut.
2. Turn the adjusting screw in until it just touches.
3. Turn the adjusting screw out three full turns.
4. Replace and tighten lock nut.
LOCK NUT
ADJUSTING SCREW
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SRS-65 Owner’s Manual
Hydraulic Oil Cooler/Compressor Oil Cooler
For reliable operation and longevity of both compressor and hydraulic system, the cooler
should be kept clean. The compressor system is protected from operation at high temperature by a switch gauge. If the compressor shuts down or is operating close to the shut
down temperature, the cooler should be cleaned. The cooler can be cleaned with compressed air, pressure washer or steam cleaner.
Maintenance Procedure
1. Turn off the compressor, hydraulic system and
truck engine to ensure that compressor is not started.
2. Discharge the receiver.
3. Remove the shroud.
4. Drain oil from the compressor.
5. Disconnect:
a. Lines to the cooler.
b. Lines to the thermo valve.
c. Electrical connection to the fan.
6. Remove the cooler.
7. Remove the fan shroud and fan from the cooler.
8. Cap the hydraulic fittings on the cooler and thermo valve.
9. Clean cooler.
10. Reinstall the cooler in reverse order.
11. Refill with oil.
12. Test run compressor and check operating temperature.
13. Check oil level and fill if necessary.
Oil Cooler
Chapter 5 - Installation
Installation
13
Component Installation
Notice: Read this Page Before Installation of the Compressor
This section pertains to the installation of the
air compressor, PTO, pump and other related items. The instructions are intended as a
guide to assist you with particular installation. These instructions will provide only general information.
Pump Assembly:
The pump assembly may either be installed
directly on the PTO or as an optional
method, may be driven by a driveline from
the PTO. Pump manufacturers provide
specific installation information for their
products and should be consulted if
questions arise. Note: A Dual or Tandem
Hydraulic Pump is recommended when
additional hydraulically operated equipment are added to the hydraulic system.
PTO Assembly:
Check with the PTO manufactures
representative for specific instructions
regarding your particular make, model, and
year of vehicle. As some trucks may require
modification of the transmission cross
member and the exhaust system, the
manufacturer’s instructions should be
followed to insure proper installation of the
PTO.
Compressor Assembly:
Prepare the mounting location of the
compressor by locating and drilling four (4)
holes, 1/2” diameter as per the mounting
pattern of the air compressor base. Using
four (4) 3/8” x 1.25 GR-5 cap screws, 3/8”
flat washer, and 3/8” nyloc nut, secure the
compressor in place. The compressor is air
cooled, and must have a clean supply of
cooling air to the fan with minimum
restrictions. Adequate space must be
provided for proper circulation of air.
Electrical Connections:
From the air pressure switch there are two
(2) wires, red and black, running to the
outside of the compressor housing. Connect
the black wire to the vehicle frame or other
suitable ground. Mount a single throw
toggle 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 12volt power supply. A third wire is required
from the air compressor switch when
connecting the speed control into the
system. (See drawing on next page)
Electric Speed Control:
An optional electric or electronic speed
control must be used to maintain proper
operating speed of the air compressor. The
engine speed control will automatically
increase from idle to preset speed when
engaged and decrease when disengaged.
14
SRS-65 Owner’s Manual
SRS-65 Electrical Installation
PRESSURE
GAUGE
TEMPERATURE
GAUGE
BLACK WIRE
RED WIRE
(NOT USED)
RED WIRE
(NOT USED)
87
BOSCH
RELAY
A
85
86
87A
30
SOLENOID
VALVE
Note:
Bosch Relay A provides power to the fan.
Bosch Relay B shuts down the compressor when
the pressure or compressor oil temperature
becomes too high.
BOSCH
RELAY
B
AIR INLET
(Model E Compressor Only)
MOTOR
MOTOR
LINE
LINE
GROUND
PN 61236
Temperature Gauge Installation
USE THIS PORT FOR
THE TEMP GAUGE
PROBE
Installation
DO NOT ATTEMPT TO INSTALL
TEMPERATURE GAUGE INTO THIS
PORT. DAMAGE WILL RESULT!
15
16
SRS-65 Owner’s Manual
Hydraulic System
The hydraulic system consists of the pump, oil reservoir, filters and hoses. Installed on the
compressor is a valve block assembly that controls the flow to the hydraulic motor. To this
block, a 1/2” high-pressure hose must be attached. This hose comes from the pressure
side of the hydraulic pump. A 3/4” minimum low-pressure return line is connected to the
oil cooler outlet and is routed to the oil reservoir. American Eagle recommends a sufficient
sized reservoir be provided that includes the proper suction and return filters. The cooler
on the compressor is designed and sized to cool the air compressor efficiently. An auxiliary oil cooler is required when additional hydraulically operated equipment are added to
the hydraulic system. Pressure on the return line exceeding 200 PSI can and will cause
damage to the filter, cooler, and components of the compressor hydraulic system.
Air System
The airline is routed using a 3/4” (200 psi) air hose. This delivery line should be free from all
obstructions. Note: There should be no check valve installed between the compressor
and the air tank. American Eagle recommends the installation of a ten gallon air tank
(minimum) to maintain proper operation of the air compressor.
PRESSURE LINE
RETURN LINE
AIR DELIVERY
Installation
Compressor Pressure Switch (RP/E Models Only)
Kick On (Step 2)
Pressure Setting
Adjustment Screw
(115-120 psi)
Location inside box of SRS Compressors
17
Kick Out (Step 1)
Pressure Setting
Adjustment Screw
(145-150 psi)
-
+
-
+
Note: Turning adjustment screws clockwise
increases psi settings. Turning adjustment screws
counterclockwise decreased psi settings.
Pressure Setting Instructions:
1. Always set the kick out pressure setting first. 145 psi minimum/150 psi maximum.
2. After kick out pressure is set, adjust the kick on screw setting 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 (Page 1).
18
SRS-65 Owner’s Manual
SRS-65P Compressor Pressure Setting
To decrease pressure, turn screw out
(counter-clockwise). To increase
pressure, turn screw in (clockwise).
Installation
Typical Hydraulic Circuit for Single Stage Pump
19
Typical Hydraulic Circuit for Tandum (Two Part) Pump
PN 30532
20
SRS-65 Owner’s Manual
Typical Hydraulic Circuit for Compressor
with Auxiliary Cooler
HYDRAULIC
RESERVOIR
FILTER
FILTER SCREEN
AUXILIARY
COOLER
SUCTION PORT
SINGLE
HYDRAULIC
PUMP
COMPRESSOR
RETURN
PRESSURE
Assembly Drawings
Chapter 6 - Assembly Drawings
SRS-65E
Compressor Assembly
PN 53887
Pages 22-23
SRS-65P
Compressor Assembly
PN 53889
Pages 24-25
21
22
SRS-65 Owner’s Manual
SRS-65E Compressor Assembly - PN 53887
51
65
71
27
42
29
70
63
61
21
49
46
28
6
13
22
57
14
74 39
63
53
62
67
66 4
50
47
73
58
15
1
31
56
29
5
33
TORQUE: 35 FT.-LBS.
TORQUE: 25 FT.-LBS.
64
59
43
29
13
68
15 69
64
34
55
60
17
29
41
30
23 24 40 25
63
19
7
32
20
4
11 26
16
8
40
74
12
54
45 72 48
18
52
67
10
1
9
44
3
2
36
2
71
35
37
38
23
Assembly Drawings
SRS-65E Compressor Assembly - PN 53887
ITEM
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
0333
0340
0342
0343
0346
0351
0352
0479
0480
0485
0521
0522
0523
0535
4591
4593
4594
5419
5735
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
DESCRIPTION
NUT 0.25-20 HHGR5 NYLOC
WASHER 0.25 FLAT
NUT 0.31-18 HH NYLOC
WASHER 0.31 USS FLAT ZINC
WASHER 0.38 FLAT
CAP SCR 0.38-16X1.00 HHGR5
WASHER 0.50 USS FLAT ZINC
CAP SCR 0.25-20X0.75 HHGR5
CAP SCR 0.25-20X1.00 HHGR5
CAP SCR 0.31-18X1.25 HHGR5
WASHER 0.25 LOCK
WASHER 0.31 LOCK
WASHER 0.38 LOCK
NUT 0.38-16 HHGR5
FTG 12 MORB PLUG HOLLOW HEX
FTG 8-8-8 MJ-FJS-MJ TEE
FTG 8-8 MJ-MORB STRAIGHT
FTG 0.50-0.25 BUSH RED BRASS
NUT SERT 0.31-18X0.50 OD
FTG 4-4XCLOSE MP-MP NIPPLE STRAIGHT
8158
BRASS
8277
FTG ST L 0.25 MNPT/0.125 FNPT SPL
12122
BOLT 0.38X1.00 EYE 567-23-ZN
12856
CAP 0.50 PIPE HEX 5406-8
FTG 8-8X2.50 MP-MP NIPPLE STRAIGHT
13579
BRASS
17583
CAP SCR 10MMX30MM HHGR5
19589
NUT SERT 0.25-20X0.38 OD
19592
WASHER 0.25 FLAT NYLON
20944
TUBE ASM 0.75 AIR/BULKHEAD SRS40 YZ
21297
FTG 8-8 MJ-MBSPPADJ 90
21298
FTG 4-4 FP-MBSPP
21299
FTG 18-8 MJ-MBSPP
21300
FTG 12-8 MJ-MBSPPADJ 90
21393
FTG 12-12 FP-MJ BULKHEAD STRAIGHT
21400
FTG 8-8 MORB-FJS STRAIGHT
21549PC PANEL GAUGE MNT SRS40
21649
GAUGE AIR SWICHGAGE PSB20PHL200
21650
GAUGE OIL TEMP TSB20TVD3006125SR240
22018
VALVE THERMO R-2323 SRS40
Defau
lt/QTY ITEM
.
4
39
6
40
2
41
8
42
2
43
2
44
4
45
4
46
2
47
4
4
48
4
49
6
50
1
51
2
52
1
53
1
54
1
55
4
56
1
1
1
1
1
4
4
6
1
4
1
1
1
1
1
1
1
1
1
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
PART
22161
DESCRIPTION
FTG 2-2 FP-FP COUPLER STRAIGHT BRASS
FTG ADAPT MBSPP/FNPT 1/2-1/2 F4OHG
22860
MOD
26025
CAP SCR 0.50-13X2.25 HHGR5
29391
CPRSR SRS NK60-2 ROTORCOMP
30667
BRKT MOTOR MNT SRS65
31030PC ANGLE MNT FRONT CPRSR SRS65
MOTOR HYD PLM3022SO-33S5-LOD/OF-N31035
C
31043
BELT GOODYEAR EAGLE PD Y1000
SPROKET GOODYEAR EAGLE PD Y-90S34539
QD
34541
FAN 16.00 PULL 12 VOLT 30102049
52650
SPROKET GOODYEAR PD Y-34S-H
53862
SHROUD SRS65 RP FAN MNT
53863
SHROUD ASM SRS65 RP
53867
COOLER OIL SRS65 AKG 1588.002
TUBE ASM 0.75 HYD COOLER/MANIFOLD
53882
SRS65 YZ
53883
TUBE ASM 0.50 COOLER/CPRSR SRS65 YZ
TUBE ASM 0.50 CPRSR/THERMVLV SRS65
53884
YZ
TUBE ASM 0.50 THERMVLV/COOLER SRS65
53885
YZ
53892PC BASE WLDMT CPRSR SRS65 RP
53913
PLATE BULKHEAD AIR OUT SRS65P
53916
HOSE ASM .75 X 15.25
56834
BUSHING H X 35MM
C0863 SWITCH PRES COMPRESSOR
C0910 CAP SCR 0.25-20X2.75 HHGR5
C1180 FTG ADAPT 8-12 F5OLO-S
C2142 FTG 12-12 MFS-MORB STRAIGHT
C2269 FTG 12-16 MFS-MORB STRAIGHT
C3075 BLOCK AL CPRSR SHD 66
C4498 FTG 12-12 MJ-MORB STRAIGHT
C4913 VALVE SOLND
C4914 VALVE RELIEF CP-200-1-B-0-A-C
C5504 VALVE RELIEF 200#
C6021 CAP SCR 0.25-20X0.75 BTNHD SS
C6106 NUT 0.50-13 HHGR5 NYLOC
C6188 BUSHING 1.00
C6245 FTG 4-2 CPRSN-MP 90 BRASS
Defau
lt/QTY
.
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
2
1
1
2
1
1
1
8
2
1
2
24
SRS-65 Owner’s Manual
SRS-65P Compressor Assembly - PN 53889
53
33
63
68
34
12
56
4
11 19
31
32
20
24
20
41
35
6
13
15
29
14
59
66
60
46
70
5
23
TORQUE: 35 FT.-LBS.
50
20
13
52
47
42
51
71 39
62
62
26
61
64
4
1
21
58
57
45
TORQUE: 25 FT.-LBS.
62
8
40
16 17 40
28
7
22
18
27
44 69 48
30
49
20
67
54
65
10
26
55
1
9
43
3
2
36
2
68
25
37
38
25
Assembly Drawings
SRS-65P Compressor Assembly - PN 53889
ITEM
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
0333
0340
0342
0343
0346
0351
0352
0479
0480
0485
0521
0522
0523
0535
12122
12856
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
DESCRIPTION
NUT 0.25-20 HHGR5 NYLOC
WASHER 0.25 FLAT
NUT 0.31-18 HH NYLOC
WASHER 0.31 USS FLAT ZINC
WASHER 0.38 FLAT
CAP SCR 0.38-16X1.00 HHGR5
WASHER 0.50 USS FLAT ZINC
CAP SCR 0.25-20X0.75 HHGR5
CAP SCR 0.25-20X1.00 HHGR5
CAP SCR 0.31-18X1.25 HHGR5
WASHER 0.25 LOCK
WASHER 0.31 LOCK
WASHER 0.38 LOCK
NUT 0.38-16 HHGR5
BOLT 0.38X1.00 EYE 567-23-ZN
CAP 0.50 PIPE HEX 5406-8
FTG 8-8X2.50 MP-MP NIPPLE STRAIGHT
13579
BRASS
17583
CAP SCR 10MMX30MM HHGR5
19589
NUT SERT 0.25-20X0.38 OD
21297
FTG 8-8 MJ-MBSPPADJ 90
21299
FTG 18-8 MJ-MBSPP
21300
FTG 12-8 MJ-MBSPPADJ 90
21393
FTG 12-12 FP-MJ BULKHEAD STRAIGHT
21400
FTG 8-8 MORB-FJS STRAIGHT
21549PC PANEL GAUGE MNT SRS40
4591
FTG 12 MORB PLUG HOLLOW HEX
4593
FTG 8-8-8 MJ-FJS-MJ TEE
4594
FTG 8-8 MJ-MORB STRAIGHT
53892PC BASE WLDMT CPRSR SRS65 RP
5419
FTG 0.50-0.25 BUSH RED BRASS
5735
NUT SERT 0.31-18X0.50 OD
7351
FTG ST TH ELBOW 45 DEG 12V5OLO
9804
DECAL SRS-65
19592
WASHER 0.25 FLAT NYLON
20944
TUBE ASM 0.75 AIR/BULKHEAD SRS40 YZ
21649
GAUGE AIR SWICHGAGE PSB20PHL200
21650
GAUGE OIL TEMP TSB20TVD3006125SR240
Defau
lt/QTY ITEM
.
4
38
6
39
2
40
8
41
2
42
2
43
4
44
4
45
2
46
4
47
4
4
48
6
49
1
50
1
51
1
52
53
1
54
4
4
4
1
1
1
1
1
3
1
1
1
1
4
1
2
6
1
1
1
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
PART
22018
22161
DESCRIPTION
VALVE THERMO R-2323 SRS40
FTG 2-2 FP-FP COUPLER STRAIGHT BRASS
FTG ADAPT MBSPP/FNPT 1/2-1/2 F4OHG
22860
MOD
26025
CAP SCR 0.50-13X2.25 HHGR5
30667
BRKT MOTOR MNT SRS65
31030PC ANGLE MNT FRONT CPRSR SRS65
MOTOR HYD PLM3022SO-33S5-LOD/OF-N31035
C
31042
BUSHING SH X 35MM
31043
BELT GOODYEAR EAGLE PD Y1000
SPROKET GOODYEAR EAGLE PD Y-90S34539
QD
34541
FAN 16.00 PULL 12 VOLT 30102049
40415
CPRSR SRS NK60 PMC
51234
VALVE RELIEF RV50-22A-O-P-50-35
52650
SPROKET GOODYEAR PD Y-34S-H
53862
SHROUD SRS65 RP FAN MNT
53863
SHROUD ASM SRS65 RP
53867
COOLER OIL SRS65 AKG 1588.002
TUBE ASM 0.75 HYD COOLER/MANIFOLD
53882
SRS65 YZ
53883
TUBE ASM 0.50 COOLER/CPRSR SRS65 YZ
TUBE ASM 0.50 CPRSR/THERMVLV SRS65
53884
YZ
TUBE ASM 0.50 THERMVLV/COOLER SRS65
53885
YZ
53913
PLATE BULKHEAD AIR OUT SRS65P
53916
HOSE ASM .75 X 15.25
C0910 CAP SCR 0.25-20X2.75 HHGR5
C2142 FTG 12-12 MFS-MORB STRAIGHT
C2269 FTG 12-16 MFS-MORB STRAIGHT
C3075 BLOCK AL CPRSR SHD 66
C4498 FTG 12-12 MJ-MORB STRAIGHT
C4913 VALVE SOLND
C5504 VALVE RELIEF 200#
C6021 CAP SCR 0.25-20X0.75 BTNHD SS
C6106 NUT 0.50-13 HHGR5 NYLOC
C6188 BUSHING 1.00
C6245 FTG 4-2 CPRSN-MP 90 BRASS
Defau
lt/QTY
.
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
4
1
1
1
1
1
8
2
1
1
26
SRS-65 Owner’s Manual
Replacement Parts
Chapter 7 - Replacement Parts
PART#
C4914
C4913
31035
52650
34538
C6188
31043
53867
C3075
20944
53882
53885
53883
53884
22018
HYDRAULIC COMPONENTS/DRIVE PARTS
DESCRIPTION
Relief Valve
Solenoid Valve
Hydraulic Motor
Sprocket (Hyd Motor)
Sprocket (Compressor)
Bushing (Hyd Motor)
Belt
Oil Cooler
Aluminum Manifold Block
Tube Assembly Air/Bulkhead 0.75
Tub Assembly Cooler/Manifold 0.75
Tube Assembly Thermo-Valve/Cooler 0.50
Tube Assembly Cooler/Compressor 0.50
Tube Assembly Compressor /Thermo-Valve 0.50
Thermo-Valve
ELECTRICAL/AIR PRESSURE COMPONENT
PART# DESCRIPTION
C0863 Pressure Switch (RP Model)
34541 Fan 16.00" Pull 12 Volt
C6072 Bosch Relay
61236 Wire Harness
21649 Air Switch Gauge
21650 Oil Temperature Gauge
C5504 Valve Relief 200# (Air)
PART#
15322
62683
15323
15324
C0087
33147
62682
AIR/OIL FILTER COMPONENTS
DESCRIPTION
Air Filter
Air Filter (SRS65P)
Oil Filter
Coalescering Filter (Separator Cartridge)
Synthetic Compressor Oil
SRS65 Compressor Service Kit (Includes all items above)
SRS65P Compressor Service Kit (Includes all items above)
PART#
36016
39815
69882
39807
39813
39814
39811
39812
39802
39803
29391
40415
COMPRESSOR COMPONENTS
DESCRIPTION
Electric Control Kit - 114317-V006
Coil - Solenoid Valve 12V DC 110755 (Electric Control)
Intake Valve Kit - (July 2008 and newer - Electric Only)
Intake Valve - 114682 (June 2008 and older - Electric Only)
Repair Kit - Intake Valve (39807) 114211 (2008 and older - Electric Only)
Repair Kit - Separator Head 114330
Kit - Bearing and Shaft Sealing 113881
Kit - Shaft Sealing 114353
Key - Shaft 103622
Wing Nut Screw - Air Filter Assembly 109915
Compressor (Air End) RP Model
Compressor (Air End) P Model
27
28
SRS-65 Owner’s Manual
Chapter 8 - Troubleshooting
Troubleshooting
If symptoms of poor performance develop, the following chart can be used as a guide to investigate and correct the
problem. When diagnosing faults in operations of the air compressor, always check that the hydraulic power source is
supplying the correct hydraulic flow and pressure that is listed in the compressor specification section of this manual.
Problem
Possible Cause
Compressor temperature.
Low
Fan not operating.
Plugged oil filter.
Compressor Shuts Down with air
Dirty cooler core.
demand:
Contaminated cooler core.
Hydraulic pressure and flow
incorrect
Worn hydraulic motor.
Compressor will not build up
pressure:
Compressor over pressures:
Compressor noisy or loud when
starting compressor in cold
weather:
Compressor synthetic oil has a
milky appearance:
Add compressor oil to level.
Check ground wire and fan switch/relay.
Replace filter.
Clean cooler fins.
Remove and clean.
Adjust and reset according to specifications.
Replace.
Air demand too great.
Tighten air hose clamps. Repair air leaks.
Air filter plugged.
Pressure switch out of
adjustment.
Faulty pressure switch.
Compressor speed too slow.
Drive belt slipping.
Service valve wide open.
Solenoid valve on.
Hydraulic Manifold valve stuck
(closed).
Defective pressure switch.
Air control line leaking.
Inlet valve stuck.
Restriction in control line
(dirt/ice).
Belt Slipping
Clean or replace.
Insufficient hydraulic system
pressure or flow.*
Compressor Stalls:
Solution
Presssure relief set too low.
Pressure relief seals leaking.
Air pressure set too high for
hydraulic system.
Solenoid valve cartridge seals
leaking on hydraulic manifold
assembly.
Hydraulic reservoir low on oil.
Ice buildup inside compressor
from condensation
Readjust to specifications.
Replace.
Check hydraulic flow and pressure.
Readjust and tighten.
Close valve.
Clean or replace.
Replace.
Check and correct.
Clean and replace.
Clean and free up.
Readjust and tighten.
Check the following:
1. Setting on supply pressure sytem relief valve.
2. Ensure adequate pressure and flow.
3. Check and see if other hydraulic systems
activated off the same hydraulic supply.
Readjust.
Replace.
Adjust pressure switch to reduce air pressure.
Replace with new cartridge.
Add to oil level.
Engage PTO and allow hydraulic fluid to
circulate and warm system up before engaging
compressor.
Coalescering/Separator
Replace cartridge and change compressor oil.
cartridge clogged or plugged.
Replace cooler, change filters and compressor
Ecessive oil level in compressor: Internal crack inside oil cooler.
oil.
*This can occur if another hydraulically activated component is used off the same pump system. Activating the secondary
component may drop hydraulic supply system pressure/flow and leave insufficient for compressor. Not: Even a momentary drop
in hydraulic supply pressure or flow may initiate compressor blowdown to commence.
29
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4)15;-5)5+- 96,<+;: 4<:; *- 15:;)33-, )5, 67-9);-, 15 )++69,)5+- >1;0 ";-33)9B: >91;;-5 15:;9<+;165: )5, +)7)+1;1-: #0- >)99)5;@ 7-916, :0)33 +6=-9
;0- .6336>15/
#>-3=#>-3=-
465;0 >)99)5;@ 65 7)9;: )5,
465;0 9-7)19 3)*69
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