ALLPOWER APC4016 User manual

2.5HP6GALLON
AIRCOMPRESSOR
FORTECHNICALSUPPORTPLEASE

AirCompressor
Tableof Contents
Topic
Safety Guidelines - Definitions
Hazard Warnings
Air Compressor
•Precautions
• Basic Air Compressor Components
• Assembling the Compressor
• Compressor Controls
• Electrical Power Requirements
• Breaking InThe Pump
• Operating Instructions
• Maintenance
•Storage
• Service
Troubleshooting
Glossary of Terms
Limited Warranty
Page
4
5
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2

Owner'sManual
WARNING! READAND UNDERSTANDALL SAFETY PRECAUTIONSIN
THISMANUAL BEFORE OPERATING.FAILURE TO COMPLY WITH
INSTRUCTIONS IN THIS MANUALCOULD RESULT IN PERSONAL
INJURY, PROPERTYDAMAGE,AND/OR VOIDINGOF YOUR
WARRANTY.ALL-POWERAMERICA WILL NOTBE LIABLEFOR ANY
DAMAGE BECAUSEOF FAILURE TO FOLLOW THESEINSTRUCTIONS.
Compressor Inspection
Prior to installation and usage, thoroughly inspect air compressor
for damage or flaws.
• Check tank, compressor, compressor motor and pump for
any signs of damage or corrosion.
• Check all screws, bolts, nuts and fasteners. Confirm that they
are secure.
• Confirm that all fittings, tank petcock and hardware are free
of paint, rust and corrosion.
• Confirm that all compressor settings are correct prior to
set-up and usage.
Air Tool Inspection
Prior to connecting to compressor and usage, thoroughly inspect
each air tool for damage or flaws.
• Check entire tool assembly for any signs of damage or
corrosion.
• Check all assembly screws, bolts, nuts and fasteners and
confirm that they are secure.
• Confirm that all fittings, bits and hardware for integrity.
• Confirm that tool settings are correct prior to connection and
usage.
3

AirCompressor
SafetyGuidelines- Definitions
This manualcontains important informationthat you need to know and
understand in order to protect YOUR SAFETY and to PREVENT
EQUIPMENT PROBLEMS. The following symbols help you recognize this
information. Please read the manual and pay attention to these sections.
WARNING!WARNINGSINDICATEA CERTAINTYORSTRONG
POSSIBILITYOFPERSONALINJURYORDEATHIFINSTRUCTIONS
ARENOTFOLLOWED.
A_ CAUTION: CAUTIONS INDICA TE A POSSIBILITY OF
EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT
FOLL 0 WED.
Note: Notes give helpful information.
WARNING!IMPROPEROPERATIONORMAINTENANCEOFTHIS
PRODUCTCOULDRESULTINSERIOUSINJURYANDPROPERTY
DAMAGE.READANDUNDERSTANDALLWARNINGSANDOPERATING
INSTRUCTIONSBEFOREUSINGTHISEQUIPMENT.WHENUSINGAIR
TOOLS,BASICSAFETYPRECAUTIONSSHOULDALWAYSBE
FOLLOWEDTOREDUCETHERISKOFPERSONALINJURY.
SaveTheseImportantSafety
Instructions!
Read and understand all ofthese safety instructions. Be
sure to retain them for future use.
4

Owner'sManual
HazardWarnings
Dust
WARNING!SOMEDUSTCREATEDBYPOWERSANDING,SAWING,
GRINDING,DRILLING,ANDOTHERCONSTRUCTIONACTIVITIES
CONTAINSCHEMICALSKNOWNTOTHESTATEOFCALIFORNIATO
CAUSECANCER,BIRTHDEFECTSOROTHERREPRODUCTIVEHARM.
These chemicalsmay include (but are not limitedto) the following:
•Lead from lead-based paints
• Crystalline silica from bricks and cement and other masonry products
• Arsenic and chromium from chemically-treated lumber
Your risk from these exposures varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals: work in a well
ventilated area, and work with approved safety equipment, always wear
MSHA/NIOSH approved, properly fitting face masks or respirators when
using such tools.
Always follow basic safety precautions when using air tools to reduce the
risk of personal injury.
Bursting
Rust can weaken the tank. Drain the condensed water from the tank after
each use to reduce rusting. If a leak is detected in the tank, replace the tank
immediately. Do not weld, drill or modify the air tank of this compressor.
Welding or modifications on the air compressor tank can severely impair
tank strength and cause an extremely hazardous condition. Welding or
modifying the tank in any manner will void the warranty.
Check the manufacturer's maximum pressure rating for air tools and
accessories. Compressor outlet pressure must be regulated so as to never
exceed the maximum pressure rating of the tool. Relieve all pressure
through the hose before attaching or removing accessories.
Do not adjust the pressure switch or relief valve for any reason. Doing so
voids all warranties. They have been preset at the factory for the maximum
pressure of this unit. Personal injury and/or property damage may result if
the pressure switch or the relief valve are tampered with.
Do not use plastic or pvc pipe for compressed air. Use only galvanized steel
pipe and fittings for compressed air distribution lines.
5

AirCompressor
HazardWarnings(cont'd)
RiskofEyeorHeadInjury
What could happen:
•Air powered equipment and power tools are capable
of propelling materials such asfasteners, metal chips,
saw dust, and other debris at high speed, which could
resultin seriouseye injury.
• Compressedair can be hazardous.The air stream
can cause injuryto softtissueareas such as eyes,
ears, etc. Particlesor objectspropelledbythestream
can cause injury.
•Toolattachmentscan become looseor breakand fly
apart propellingparticlesat theoperatorand othersin
thework area.
How toprevent it:
•Alwayswear ANSI approvedZ87.1 safety glasses withside shields.
•Never leaveoperatingtoolunattended.Disconnectair hosewhen toolis
notin use.
•Foradditionalprotection, usean approvedface shieldin additionto
safety glasses.
•Make surethat anyattachmentsare securelyassembled.
•Never pointanynozzle or sprayertowarda personor any partofthe
body.Equipmentcan cause seriousinjuryifthe spray penetratesthe
skin.
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Owner'sManual
HazardWarnings(cont'd)
RiskofFireorExplosion
What could happen:
•Abrasive tools such as sanders and grinders, rotating
tools such as drills, and impact tools such as nailers,
staplers, wrenches, hammers, and reciprocating saws
are capable of generating sparks which could result in
ignition of flammable materials.
• It is normal for the compressor motor and pressure
switch to produce sparks while operating. If sparks
come into contact with vapors from gasoline or other
solvents, they may ignite, causing fire or explosion.
• Exceeding the maximum pressure rating of tools or
accessories could cause an explosion resulting in
serious injury.
How to prevent it:
• Never operate tools near flammable substances such as gasoline,
cleaning solvents, etc.
• Work in a clean, well ventilated area free of combustible materials.
•Never useoxygen, carbondioxide or otherbottled gasesas a power
source for air tools.
• Use compressedair regulatedto maximumpressure at or below the
ratedpressureof anyattachments.
•Never connectto anair sourcethatis capableofexceeding200 psi.
•Alwaysverify priorto usingthe toolthatthe air sourcehasbeen
adjustedtothe rated air pressure range.
•Never sprayflammable liquidsin a confinedarea. Do not spraywhere
sparksor flame are present.
•Do notsmokewhilespraying.
•Keep compressor as far from spray area as possible.
7

AirCompressor
HazardWarnings(cont'd)
RiskofHearingLoss
What could happen:
•Long term exposure to noise produced from the
operation of air tools can lead to permanent hearing
loss.
How to prevent it:
Always wear ANSI $3.19 hearing protection when usinga compressor.
HazardRiSkto Breathing/Inhalation
What could happen:
• Abrasive tools such as grinders, sanders, and cut-off
tools generate dust and abrasive materials which can
be harmful to human lungs and respiratory system.
• Some materials suchas adhesives and tar contain chemicals whose
vapors could cause serious injury with prolonged exposure.
How to prevent it:
• Always wear MSHA/NIOSH approved, properly fitting face mask or
respirator when using such tools. Read all instructions and be sure that
your respirator mask will protect you.
• Always work in a clean, dry, well ventilated area.
• Never directly inhale the compressed air produced by a compressor. It is
not suitable for breathing purposes.
• Be certain to read all labels when you are spraying paints or toxic
materials, and follow the safety instructions.
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Owner'sManual
HazardWarnings(cont'd)
RiskofInjury
What could happen:
•Tools leftunattended,or with theair hoseattached
can be activated by unauthorized persons leading to
their injury and/or injury to others.
• Air tools can propel fasteners or other materials
throughout the work area.
• A wrench or key that is left attached to a rotating part
of the tool increases the risk of personal injury.
• Using inflator nozzles for duster applications can
cause serious injury.
• Air toolscanbecome activatedby accident during
maintenance or tool changes.
• Air tools can cause the work-piece to move upon
contact leading to injury.
• Loss of control of the tool can lead to injury to self or
others.
•Poor quality, improper, or damaged tools such as
grinding wheels, chisels, sockets, drills, nailers,
staplers, etc., can fly apart during operation,
propelling,particles throughout the work area causing
senousinjury.
• Fasteners could ricochet or be propelled causing
serious injury or property damage.
• Improperly maintained tools and accessories can
cause seriousinjury.
• There is a riskof burstingifthetoolis damaged.
•The compressor unitstartsautomatically.Serious
injurycouldoccurfrom contact with movingparts.
9

AirCompressor
HazardWarnings(cont'd)
RiskofInjury(cont'd)
How toprevent it:
•Remove air hose when toolisnot inuse and storetool in securelocation
away from reach ofchildrenand or untrainedusers.
• Useonlyparts,fasteners,and accessoriesrecommendedbythe
manufacturer.
• Keep workarea clean and free ofclutter. Keep childrenand others
away from workarea duringoperationof thetool.
•Keep workarea well lit.
•Remove adjustingkeysand wrenchesbeforeturningthe toolon.
•DO NOT use inflatornozzlesfor dusterapplications.
• Remove air hoseto lubricateor add grindingattachments,sanding
discs,drills,etc.to the tool.
•Never carrythetool bythe hose.
•Avoidunintentionalstarting.
•Repairservicingshouldbe doneonlyby an authorizedservice
representative.
•Useclampsor otherdevicesto preventmovement.
•Never operatetoolwhileunderthe influenceofdrugsor alcohol.
•Don'toverreach. Keep properfooting and balanceof alltimes.
•Keep handlesdry,clean andfree from oil and grease.
•Stay alert. Watchwhat you are doing. Use common sense. Do not
operatetoolwhen you are tired.
•Always usetoolattachmentsrated for the speed ofthe powertool.
•Never usetoolswhichhavebeen dropped,impactedor damaged by
use.
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Owner'sManual
HazardWarnings(cont'd)
RiskofInjury(cont'd)
• Useonly impact grade socketson an impactwrench.
• Do not apply excessive force to the tool. Letthe tool perform the work.
•Never pointdischargeoftoolat selfor others.
•Do not pulltriggerunlesstoolcontactsafetydevice isagainstwork
surface.
•Never attemptto drivefasteners intohardsurfacessuchas steel,
concrete,or tilewhen usingairtools.
•Takecare to avoiddrivinga fastener on top ofanotherfastener.
•Positiontoolcarefullysothat fasteners willbedeliveredtothe proper
location.
•Useonly accessoriesidentifiedbythe manufacturerto be used with
specifictools.
•Maintainthetoolwithcare.
•Keep a cuttingtoolsharpand clean. Aproperlymaintainedtool,with
sharpcuttingedges reducesthe riskof binding and iseasierto control.
•Check for misalignment of bindingor movingparts,breakageof parts,
and anyotherconditionthateffectsthe tool'soperation.Ifdamaged,
havethetoolservicedbeforeusing.
•Useof an accessorynotintendedfor use withthespecifictools
increasesthe riskof injuryto persons.
•Alwaysshut offthe compressor,removethe plugfrom the outlet,and
bleedall pressurefrom the systembeforeservicingthecompressor,and
when the compressoris notin use.
•Do notoperatethe unitwiththe shroudremoved.
11

AirCompressor
HazardWarnings(cont'd)
Riskof ElectricShock
What could happen:
• Using air tools to attach electrical wiring can result in
electrocution or death.
• Improper electrical connections can result in
fires,electrocution, or death.
This tool is not provided with an insulated gripping surface. Contact with
a "live" wire makes exposed metal tool parts "live", resulting in possible
electrocution or death.
Fasteners coming in contact with hidden electrical wiring could cause
electrocution or death.
How to prevent it:
• Never attach electrical wiring with energized tools.
• Avoid body contact with grounded surfaces such as pipes, radiators,
ranges, and refrigerators. There is an increased risk of electric shock if
your body is grounded.
• Thoroughly investigate the work piece for possible hidden wiring before
performing work.
• A licensed electrician in accordance with all local and national codes
must install all wiring.
• Never use an electric air compressor outdoors when it is raining or on a
wet surface, as it may cause an electric shock.
12

Owner'sManual
HazardWarnings(cont'd)
RiskofEntanglement
What could happen:
•Tools containing moving elements or driving other
moving tools (grinding wheels, sockets, sanding
discs, etc.) can become entangled in hair, clothing,
jewelry, and other loose objects, resulting in injury.
How to prevent it:
Neverwear loose fitting clothes,or apparel whichcontains loosestraps
or ties, etc. which could become entangled in moving parts.
Remove any jewelry, watches, identifications, bracelets, necklaces, etc.
which might become caught by the tool.
Keep hands away from moving parts. Tie up or cover long hair.
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AirCompressor
HazardWarnings(cont'd)
Riskof Cutor Burns
What could happen:
•Tools which cut, shear, drill, staple punch, chisel, etc.
are capable of causing serious injury.
• The pump and manifold generate high temperatures.
How to prevent it:
Keep the working part of the tool away from hands and body.
•Do not touch the pump, manifold or transfer tube while the pump is
running.Allowthem to cool before handling or servicing.
• Keep children away from the compressor at all times.
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Owner'sManual
Compressor
Item Value
Model Number APC4016
Peak H.P.(CV) 3.5
Tank Capacity 6
Gallons/Liters
Voltage/Amps/Phase 115/2.6/1
Kick-In Pressure 80
Kick-Out Pressure 100
WARNING! THE POWER CORDON THIS PRODUCT CONTAINSLEAD,
ACHEMICAL,KNOWN TO THE STATE OF CALIFORNIA TO CAUSE
CANCERAND BIRTH DEFECTS OR OTHER REPRODUCTIVEHARM.
WASHHANDSAFTER HANDLING.
Precautions
•Drain the moisture from thetankdaily to help prevent corrosion.
•Pullthe pressurereliefvalve ringdailyto ensureproper function and
clear possible obstructions.
•To provideproperventilationfor cooling,thecompressormustbe keptat
least12 inches(31 cm) from the nearestwall, in a well-ventilatedarea.
•Fastenthe compressorsecurelyand releasetank pressurebefore
transporting.
•Protectthe air hose and electriccordfrom damage and puncture.
Inspectthemweekly for weak orwornspots,and replace ifnecessary.
•To reducethe riskof electricshock,do notexpose to rain. Store indoors.
•Never operatethe compressorifthe powercordor plugare damaged.
Take theequipmentto the nearestAuthorized Service Center, and a
specialisttechnicianwillreplace it.
15

Owner'sManual
Compressor(cont'd)
BasicAir CompressorComponents
The basic componentsofthe air
compressorare theelectricmotor,pump,
pressureswitch,and tank.The electric
motor(see A) powersthe pump.The
electricmotoris equippedwith an
overloadprotectorand an automatic
reset. Ifthe motorbecomes overheated,
the overloadprotectorwillshut itdownto
preventdamage to the motor.When the
motorsufficientlycools, itwill
automaticallyrestart.
A&B
C
The pump (see B) compressesthe air
and discharges itintothe tank.
The tank (see C) stores the compressed
air.
The pressure switch(located internally)shutsdown the motor and relievesair
pressureinthe pumpand transfertube when theair pressurein the tank
reachesthe kick-out pressure. As compressedair is usedand the pressure
level in thetankdropstothe kick-inpressure,the pressureswitchrestartsthe
motorautomatically,withoutwarning,and the pump resumescompressingair.
AssemblingtheCompressor
1Unpack the air compressor.Inspectthe unitfor damage. Ifthe unithas
been damaged in transit,contact the carrier and completea damage
claim.Do this immediatelybecause there are time limitationsto
damaged claims.The carton shouldcontain:
o Air compressor
,o Operator and parts manuals
,_ Handle
o Wheel Assembly
16

AirCompressor
m
Compressor(cont'd)
AssemblingtheCompressor(cont'd)
2
3
4
Tightenthe handleintoitsposition
with screwsincluded.
Check the compressor's serial labelto ensure thatyou have received
the model ordered, and that it has the required pressure rating for its
intended use.
Locatethe compressor accordingto the following guidelines:
aPosition the compressor near a grounded electrical outlet (see
GROUNDING INSTRUCTIONS, above).
bThe compressor must be at least 12 inches (31 cm) from any wall or
obstruction, in a clean, well-ventilated area, to ensure sufficient air
flow and cooling.
c In cold climates,storeportable compressorsinaheated building
when notin use. This willreduceproblemswith motorstartingand
freezingofwater condensation.
d Removethe compressorfrom theshippingpalletor cartonand place
itonthe flooror a hard, level surface.The compressormustbe level
to ensureproperdrainageof the moistureinthe tank.
Connect an air hose tothe compressorhoseoutlet.
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Owner'sManual
Compressor(cont'd)
CompressorControls
•Power switch: This switchturns the compressorpowerON and OFF.
•Pressure switch : Thisswitchturnson the compressor.Itisoperated
automaticallywhen the powerswitchisin the ON position,itallowsthe
compressor tostartup or shutdownautomatically,withoutwarning,
dependinguponair demand.
•Pressure Relieve Valve: If the pressureswitchdoes not shutdown
the motorwhen pressurereachesthe preset level,thisvalvewill
popopenautomaticallyto preventover pressurization.To operate
manually,pullthe ringon the valveto relieve air pressureinthe tank.
•Tank Pressure Gauge: Thisgauge measures the pressurelevelofthe
air storedinthe tank. Itisnotadjustablebythe operator,and does not
indicatelinepressure.
•Air Pressure Regulator : Thisair pressureregulatorenablesyou to
adjustlinepressuretothe toolyou are using.
WARMNG!NEVEREXCEEDTHEMAXIMUMWORKINGPRESSUREOF
THETOOL.TURNTHEKNOBCLOCKWISETOINCREASEPRESSURE,
ANDCOUNTERCLOCKWISETODECREASEPRESSURE.
18

AirCom
Compressor(cont'd)
CompressorControls(cont'd)
•Regulated pressure gauge: This gauge measuresthe regulated
outletpressure.
•Regulated pressure quick connect coupler: This couplerconnects
to the regulatedoutletpressure.Toconnect air hose, pushcouplerin.
Todisconnectair hose,pullthe couplercollarback and separate the coupling.
ElectricalPowerRequirements
ElectricalWiring
Refer to the air compressor's seriallabelforthe unit'svoltageand
amperage requirements.
Use a dedicatedcircuit.Forbest performanceand reliablestarting,the air
compressor mustbe pluggedintoa dedicated circuit,as closeas possible
tothefuseboxor circuitbreaker.The compressor willusethefull capacityof
a typical15 amp householdcircuit.Ifotherdevicesare on the same circuit,
the compressormay fail tostart. Lowvoltageor an overloadedcircuitcan
resultinsluggishstartingthat causesthe motoroverloadprotectionsystem
circuitbreaker totrip, especiallyincoldconditions.
Note: A circuitbreaker is recommended.If theair compressor is
connectedtoa circuitprotected bya fuse, usedualelement time
delay fuses(Buss Fusetrontype "1" only).
Note: Avoid use of extensioncords.If using an extensioncord
is necessary, be sure to use an extension with the correct
specifications.
For optimum performance, plug the compressor powercord directlyintoa
groundedwall socket.Do not usean extensioncord unlessabsolutely
necessary.Instead,use a longerair hoseto reach thearea where the air is
needed.
If useofan extension cord cannotbe avoided,thecord should be no longer
than 100 feet and be a minimum wire size of 14 gauge (AWG).
19

Owner'sManual
Compressor(cont'd)
ElectricalPowerRequirements(cont'd)
ExtensionCord
Use the chart on the rightfor
the proper extension cord length.
Useonlya 3-wire extension cord
that has a3-blade groundingplug,
and a 3-slot receptaclethatwillac-
cept theplugof theproduct.Make
sure yourextensioncord isin good
condition. An undersizedcordwill
cause a drop in linevoltageas well
as a lossof powerand overheating.
The smallerthe gauge number,the
heavierthe cord.
Amp Length of
Rating Cord in Feet
(120Volts) 25' I 50' 100' t50'
10-12 16 I 14 10 8
12-14 16 I 12 10 8
14-16 16 I 12 10 8
16-18 14 I 12 88
18-20 14 I 12 8 8
GroundingInstructions
This product shouldbe grounded.In the eventof an electricalshortcircuit,
groundingreducesthe riskofelectricshockbyprovidingan escapewire for
the electriccurrent.
This product isequipped with a cord having agrounding wire withan
appropriategroundingplug.The plugmustbe pluggedintoan outletthat is
properlyinstalledand groundedinaccordancewithall localcodesand
ordinance.
_k ARNING!IMPROPERINSTALLATIONOFTHEGROUNDINGPLUG
CANRESULTINARISKOFELECTRICSHOCK.IF REPA/ROR
REPLACEMENTOFTHECORDORPLUGISNECESSARY,DONOT
CONNECTTHEGROUNDINGWIRETOEITHERFLATBLADETERMINAL.
THEWIREINSULATIONHAVINGANOUTERSURFACETHATISGREEN
WITH,ORWITHOUT,YELLOWSTRIPESISTHEGROUNDINGWIRE.
This product isfor use on a nominal 110 voltcircuit. An outlet with a ground-
ing plug must be used.
Make sure thatthe productisconnectedto an outlethaving the same con-
figurationas the plug.No adaptershouldbe usedwith thisproduct.
Do not alter the plug to fit into a non-grounded or 2-slot receptacle.
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