Craftsman 16781 - Professional 80 Gal. Vertical Air... User manual

Owner's Manual
ICRRFTgMRNI
Oil Lube Two Stage
Air Compressor
AiR COMPRESSOR
=Safety Guidelines
=Assembly
= Operation
=Maintenance
=Troubleshooting
=Repair Parts
CAUTION; Read the Safety Guidelines
and All Instructions Carefully Before
Operating.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Visit our Craftsman website: www.sears.com/craftsman
1000002023 5J2eJo7

WARRANTY................................................ 2
SPECiFiCATiONCHART...................................... 2
SAFETYGUiDELiNES...................................... 3-8
GLOSSARY................................................ 9
DUTYCYCLE............................................... 9
ACCESSORIES............................................. 9
ASSEMBLY............................................... 10
iNSTALLATiON......................................... 10-12
OPERATION............................................ 13-15
MAINTENANCE......................................... 16-19
SERVICEANDADJUSTMENTS............................ 19-20
STORAGE................................................ 20
TROUBLESHOOTING GUIDE .............................. 21-23
REPAIR PARTS ......................................... 24-27
ESPA_IOL .............................................. 28-49
REPAIR PROTECTION AGREEMENTS ......................... 51
HOW TO ORDER REPAIR PARTS ...................... back cover
ONE YEAR FULL WARRANTY
If this product fails due to a defect in material or workmanship within one year
from the date of purchase, Sears will at its option repair or replace it free of
charge. Contact Sears at 1-800-4-MY-HOME ®to arrange for repair, or return it
to the place of purchase for replacement.
If this product is used for commercial or rental purposes, this warranty applies
for only ninety days from the date of purchase.
This warranty gives you specific legal rights and you may have other rights
which vary from state to state.
Sears, Roebuck and Co., Dept. 817WA, Hoffman Estates, IL 60179
Model No.
Running Horsepower
Voltage-Single Phase
Minimum Branch Circuit Requirement
Fuse Type
Air Tank Capacity, Gallons
Approximate Cut-in Pressure
Approximate Cut-out Pressure
SCFM @ 100 psig
SCFM @ 175 psig
919.1678t0
*5.3
240V
30 amps
Time Delay
80 ASME, Vertical
140 PSIG
175 PSIG
"13.3
"12.8
* Tested per ISO 1217
Refer to Glossary for abbreviations.
1000002023 2 ENG

This manual contains information that is important for you to know and under-
stand. This information relates to protecting YOUR SAFETY and PREVENTING
EQUIPMENT PROBLEMS. To help you recognize this information, we use the
symbols below. Please read the manual and pay attention to these symbols.
_ Indicates an
imminently hazardous
situation which, if not avoided, wil__l
result in death or serious in'_.
_ Indicates a potentially
hazardous situation
which, if not avoided, could result in
death or serious injury.
_ Indicates a potentially
hazardous situation
which, if not avoided, may result in
minor or moderate injury.
_Used without the
safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may result
tn property damage.
_Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities contains
chemicals known to the State of California to cause cancer, birth defects or
other reproductive harm. Some example of these chemicals are:
• lead from lead-based paints
• crystalline silica from bricks and cement and other masonry products
o 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 awell
ventilated area, and work with approved safety equipment, always wear
OSHA/MSHA/NIOSH approved, properly fitting face mask or respirator
when using such tools.
When using air tools, basic safety precautions should always be followed to
reduce the risk of of personal injury.
_This product contains chemicals, known to the State of
California to cause cancer, and birth defects or other
reproductive harm. Wash hands after handling.
Do not operate this unit until you read and #x-_l
understand this instruction manual for safety,
operation and maintenance instructions.
SAVE THESE INSTRUCTIONS
WHAT CAN HAPPEN = HOW TO PREVENT IT
It is normal for electrical contacts Always operate the compressor
within the motor and pressure in a well ventilated area free of
switch to spark, combustible materials, gasoline, or
solvent vapors.
3 ENG 1000002023

If electrical sparks from compressor
come into contact with flammable
vapors, they may ignite, causing fire
or explosion.
Restricting any of the compressor
ventilation openings will cause
serious overheating and could cause
fire.
• Unattended operation of this
product could result in personal
injury or property damage. To
reduce the risk of fire, do not
allow the compressor to operate
unattended.
Ifspraying flammable materials, locate
compressor at least 20 feet (6.1 m)
away from spray area. An additional
length of air hose may be required.
Store flammable materials in a secure
location away from compressor.
Never place objects against or on
top of compressor.
Operate compressor in an open area
at least 12" (30.5 cm) away from
any wall or obstruction that would
restrict the flow of fresh air to the
ventilation openings.
Operate compressor in a clean, dry
well ventilated area. Do not operate
unit indoors or in any confined area.
Always remain in attendance with
the product when it is operating.
Disconnect electrical supply when
not in use.
__ RISK TO BREATHING (ASPHYXIATION)
WHAT CAN HAPPEN
The compressed air directly from
your compressor is not safe for
breathing. The air stream may
contain carbon monoxide, toxic
vapors, or solid particles from the air
tank. Breathing these contaminant's
can cause serious injury or death.
Sprayed materials such as paint,
paint solvents, paint remover,
insecticides, weed killers, may
contain harmful vapors and poisons.
HOW TO PREVENT IT
Air obtained directly from the
compressor should never be used to
supply air for human consumption.
In order to use air produced by this
compressor for breathing, suitable
filters and in-line safety equipment
must be properly installed. In-line
filters and safety equipment used
in conjunction with the compressor
must be capable of treating air to all
applicable local and federal codes
prior to human consumption.
Work in an area with good cross
ventilation. Read and follow the
safety instructions provided on the
label or safety data sheets for the
materials you are spraying. Always
use certified safety equipment: OSHA/
MSHA!NIOSH respiratory protection
designed for use with your specific
application.
1000002023 4 ENG

I_1_ ISK OF SERIOUS iNJURY OR PROPERTY DAMAGE
WHEN TRANSPORTING COMPRESSOR
WHAT CAN HAPPEN ! HOW TO PREVENT iT
Oil can leak or spill and could • Always place compressor on a
result in fire or breathing hazard; protective mat when transporting
serious injury or death can result, oil I to protect against damage to vehicle
leaks will damage carpet, paint or from leaks. Remove compressor
other surfaces n veh c es or tra ers. from vehicle immediately upon
_]_ RISK OF BURSTING
Air Tank: The air tank on your Air Compressor is designed and may be UM
coded (for units with air tanks greater than 6 inch diameter) according to ASME
Section VIII, Div. 1 rules. All pressure vessels should be inspected once every
two years. Tofind your state pressure vessels inspector, look under the Division
of Labor and Industries in the government section of a phone book.
The following conditions could lead to a weakening of the air tank, and result in
a violent air tank explosion:
WHAT CAN HAPPEN
Failure to properly drain condensed
water from air tank, causing rust and
thinning of the steel air tank.
Modifications or attempted repairs to
the air tank.
Unauthorized modifications to the
safety valve or any other components
which control air tank pressure.
Excessive vibration can weaken the
air tank of a stationary compressor
and cause an explosion.
Attachments & accessories:
Exceeding the pressure rating of
air tools, spray guns, air operated
accessories, tires, and other I
inflatables can cause them to I
explode o! f!y apart, and could result
n set ous nury.
HOW TO PREVENT iT
Drain air tank daily or after each use.
Ifair tank develops a leak, replace it
immediately with a new air tank or
replace the entire compressor.
Never drill into, weld, or make any
modifications to the air tank or its
attachments. Never attempt to
repair a damaged or leaking air tank.
Replace with a new air tank.
The air tank is designed to withstand
specific operating pressures.
Never make adjustments or parts
substitutions to alter the factory set
operating pressures.
The compressor must be properly
mounted, see "Anchoring" under
Installation.
Follow the equipment manufacturers
recommendation and never exceed
the maximum allowable pressure
rating of attachments. Never use
compressor to inflate small low
pressure objects such as children's
toys, footballs, basketballs, etc.
5 ENG 1000002023

[__ RISK OF ELECTRICAL SHOCK
WHAT CAN HAPPEN
•Your air compressor is powered by
electricity. Like any other electrically
powered device, if it is not used
properly it may cause electric shock.
• Repairs attempted by unqualified
personnel can result in serious injury
or death by electrocution.
Electrical Grounding: Failure to
provide adequate grounding to this
product could result in serious injury
or death from electrocution. Refer to
"Grounding Instructions" paragraph
in the Installation section.
HOW TO PREVENT iT
Never operate the compressor
outdoors when it is raining or in wet
conditions.
Never operate compressor with
protective covers removed or
damaged.
Any electrical wiring or repairs
required on this product should be
performed by authorized service
center personnel in accordance with
national and local electrical codes.
Make certain that the electrical circuit
to which the compressor is connected
provides proper electrical grounding,
correct voltage and adequate fuse
protection.
i, D
WHAT CAN HAPPEN
The compressed air stream can
cause soft tissue damage to
exposed skin and can propel dirt,
chips, loose particles, and small
objects at high speed, resulting in
property damage or personal injury.
__ RiSK FROM FLYING OBJECTS
HOW TO PREVENT iT
Always wear certified safety
equipment: ANSI Z87.1 eye
protection (CAN/CSA Z94.3)
with side shields when using the
compressols
Never point any nozzle or sprayer
toward any part of the body or at
other people or animals.
Always turn the compressor off
and bleed pressure from the air
hose and air tank before attempting
maintenance, attaching tools or
accessories.
1000002023 6 ENG

__ RISK OF HOT SURFACES
,, WHAT CAN HAPPEN !. HOW TO PREVENT iT
Touching exposed metal such as I Never touch any exposed metal
the compressor head, engine head, parts on compressor during or
engine exhaust or outlet tubes, can immediately after operation.
result in serious burns. Compressor will remain hot for
several minutes after operation.
• Do not reach around protective
I shrouds or attempt maintenance
until unit has been allowed to cool.
___ RiSK FROM MOVING PARTS
WHAT CAN HAPPEN
Moving parts such as the pulley,
flywheel, and belt can cause serious
injury if they come into contact with
you or your clothing.
Attempting to operate compressor
with damaged or missing parts or
attempting to repair compressor
with protective shrouds removed
can expose you to moving parts and
can result in serious injury.
HOW TO PREVENT iT
Never operate the compressor
with guards or covers which are
damaged or removed.
Keep your hair, clothing, and gloves
away from moving parts. Loose
clothes, jewelry, or long hair can be
caught in moving parts.
Air vents may cover moving parts
and should be avoided as well.
Any repairs required on this product
should be performed by authorized
service center personnel.
7 ENG 1000002023

[__ RiSK OF UNSAFE OPERATION
WHAT CAN HAPPEN ! HOW TO PREVENT iT
•Unsafe operation of your air I = Review and understand all
compressor could lead to serious inju- I instructions and warnings in this
ry or death to you or others, manual.
• Become familiar with the operation
and controls of the air compressor.
Keep operating area clear of all
persons, pets, and obstacles.
Keep children away from the air
compressor at all times.
Do not operate the product when
fatigued or under the influence of
alcohol or drugs. Stay alert at all
times.
Never defeat the safety features of
this product.
Equip area of operation with afire
extinguisher.
Do not operate machine with missing,
broken, or unauthor zed parts.
[__ RISK OF INJURY FROM LIFTING
WHAT CAN HAPPEN I HOW TO PREVENT iT
I
oSerious injury can result from = The compressor is too heavy to
attempting to lift too heavy an I be lifted by one person. Obtain
object, assistance from others before lifting.
RiSK FROM NOISE
WHAT CAN HAPPEN • HOW TO PREVENT iT
" Under someconditions and duration Alwayswearcertified safety equipment:
of use, noise from this product may ANSI$12.6 (S3.19)hearingprotection.
contribute to hearingloss.
SAVE THESE INSTRUCTIONS
1000002023 8 ENG

Become familiar with these terms
before operating the unit.
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per min-
ute; a unit of measure of air delivery.
PSlG: Pounds per square inch gauge;
a unit of measure of pressure.
Code Certification: Products that
bear one or more of the following
marks: UL, CUL, ETL, CETL, have
been evaluated by OSHA certified
independent safety laboratories and
meet the applicable Underwriters
Laboratories Standards for Safety.
Cut=in Pressure: While the motor is
off, air tank pressure drops as you
continue to use your accessory. When
the tank pressure drops to a certain
low level the motor will restart auto-
matically. The low pressure at which
the motor automatically restarts is
called "cut-in" pressure.
Cut-Out Pressure: When an air
compressor is turned on and begins
to run, air pressure in the air tank
begins to build. It builds to a certain
high pressure before the motor auto-
matically shuts off - protecting your
air tank from pressure higher than its
capacity. The high pressure at which
the motor shuts off is called "cut-out"
pressure.
Branch Circuit: Circuit carrying elec-
tricity from electrical panel to outlet.
To Lock Out Power: Place a lock on
the line power switch so no one else
can turn on the power.
This air compressor pump is capable average duty cycle be maintained; that
of running continuously. However, to is, the air compressor pump should
prolong the life of your air compressor, not run more than 30-45 minutes in
it is recommended that a 50%-75% any given hour.
This unit is capable of powering the following Accessories. The accessories are
available through the current Power and Hand Tool Catalog or full-line Sears
stores.
Accessories
•in Line Filter
•Tire Air Chuck
Quick Connector Sets (various
sizes)
Air Pressure Regulators
Oil Fog Lubricators
Air Hose: 1/4", 3/8" or 1/2" I.D. in
various lengths
Refer to the selection chart located on
the unit to select the tools this unit is
capable of powering.
_The use of any
other accessory
not recommended for use with
this tool could be hazardous. Use
only accessories rated equal to
or higher than the rating of the air
compressor.
9 ENG 1000002023

Contents of Carton
1 - Air Compressor
1 - Parts bag containing:
1 - Owner's Manual
4 - 5/8" Washers
1 - Conduit Connector
Tools Required for Assembly
1 - 9/16" socket or open end wrench
1 - Electric drill
Unpacking
1. Remove all packaging.
_lt may be necessary
__ to brace or support
one side of the outfit when removing
the pallet because the air compressor
will have a tendency to tip.
2. Remove and discard the (4)
screws and washers holding the
compressor to the pallet.
3. With the help of another person
carefully remove air compressor
from pallet and place on a level
surface.
_This compressor was
shipped with oil in
the pump crankcase. Check oil before
operating air compressor, see Check
Oil under Maintenance.
HOW TO SET UP YOUR UNIT
Location of the Air Compressor
• Locate the air compressor in a
clean, dry, and well ventilated
area.
Located the air compressor at
least 12" (30.5 cm) away from
the wall or other obstructions
that will interfere with the flow
of air.
Locate the air compressor as
close to the main power supply
as possible to avoid using long
lengths of electrical wiring.
NOTE: Long lengths of electri-
cal wiring could cause power
loss to the motor.
The air filter must be kept clear
of obstructions which could
reduce air flow to the air com-
presso£
Anchoring of the Air Compressor
_Risk of Bursting.
Excessive
Vibration can weaken the air tank
and cause an explosion. The
compressor must be properly
mounted.
The air compressor MUST be bolted to
a solid, level surface.
Hardware needed:
4 - Concrete anchors
(not supplied)
4 - 3/8" Lag screw to fit concrete
anchors
(not supplied)
4 - 5/8" Washer (supplied)
shims (if needed)
1. Place the air compressor on a
solid, level surface.
2. Mark the surface using the holes
in the air compressor feet as a
template.
3. Drill holes in the surface for the
concrete anchors. Install concrete
anchors.
4. Line-up holes in surface with holes
in air compressor feet.
5. Place the (4) washers (supplied)
between the floor and air com-
pressor feet. If needed, solid
shims may be placed between the
washers and floor to evenly dis-
tribute weight on all four feet. See
next figure.
1000002023 10 ENG

T
.......3/8" Lag
........ Screw
,, ......./(not supplied)
5/8 Washer ,..... /..
(supplied) _ __
_ ,_12
Shim Under _urface Line
Washer Concrete Anchor
(net supplied) (not supplied)
6. Place the (4) 3/8" lag screws
through the air compressor feet,
washers, shims, and into the
anchors.
7. Torque 3/8" lag screws to
7 - 10 ft. Ibs.
Wiring Instructions
_Risk of Electrical
Shock. Improper
electrical grounding can result in
electrical shock. The wiring should
be done by a qualified electrician
A qualified electrician needs to knows
the following before wiring:
1. The amperage rating of the electri-
cal box should be adequate. Refer
to the Specification Chart for this
information.
2. The supply line should have the
same electrical characteristics
(voltage, cycle, phase) as the
motor. Refer to the motor name-
plate, on side of motor, for this
information.
NOTE: The wiring must be the same
as the motor nameplate voltage plus
or minus 10%. Refer to local codes for
recommended wire sizes, correct wire
size, and maximum wire run; undersize
wire causes high amp draw and over-
heating to the motor.
_Risk of Electrical
Shock. Electrical
wiring must be located away from
hot surfaces such as manifold
assembly, compressor outlet tubes,
heads, or cylinders.
GROUNDING iNSTRUCTIONS
This product should be connected to
a metallic, permanent wiring system,
of an equipment-grounding terminal
or lead on the product.
Voltage and Circuit Protection
Refer to the specification chart for the
voltage and minimum branch circuit
requirements.
Air Distribution System
_Risk of Bursting.
Plastic or PVC
pipe is not designed for use with
compressed air. Regardless of its
indicated pressure rating, plastic
pipe can burst from air pressure.
Use only metal pipe for air
distribution lines.
The next figure represents a typical
air distribution system. The following
are tips to remember when setting up
the air compressor's air distribution
system.
• Use pipe that is the same size as
the air tank outlet. Piping that is
too small will restrict the flow of
air.
• If piping is over 100 feet (30.5 m)
long, use the next larger size.
• Bury underground lines below
the frost line and avoid pockets
where condensation can gather
and freeze. Apply pressure before
underground lines are covered to
make sure all pipe joints are free
of leaks.
• A flexible coupling is recommend-
ed to be installed between the air
discharge outlet and main air dis-
tribution line to allow for vibration.
® A separate regulator is recom-
mended to control the air pres-
sure. Air pressure from the tank
is usually to high for individual air
driven tools.
11ENG 1000002023

TYPICAL COMPRESSED
AiR DiSTRiBUTiON SYSTEM
DRAIN COCK
VALVE
AIR
COMPRESSOR
1000002023 12 ENG

KNOW YOUR AIR COMPRESSOR
READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING
YOUR UNIT. Compare the illustrations with your unit to familiarize yourself with
the location of various controls and adjustments. Save this manual for future ref-
erence.
DESCRiPTiON OF OPERATION
Become familiar with these controls
before operating the unit.
On/Auto/Off Lever: Turn this switch
"On/Auto" to provide automatic power
to the pressure switch and "Off" to
remove power at the end of each use.
Pressure Switch: The pressure switch
automatically starts the motor when
the air tank pressure drops below the
factory set "cut-in" pressure. It stops
the motor when the air tank pressure
reaches the factory set "cut-out" pres-
sure.
Safety Vamve: Ifthe pressure switch
does not shut off the air compressor
at its "cut-out" pressure setting, the
safety valve will protect against high
pressure by "popping out" at its fac-
tory set pressure (slightly higher than
the pressure switch "cut-out" setting).
Tank Pressure Gauge: The tank
pressure gauge indicates the reserve
air pressure in the tank.
Globe Valve: Opens and closes air
discharge valve. Turn knob counter-
clockwise to open and clockwise to
close.
Regulator (sold separately, not
shown): An air pressure regulator or a
separate air transformer which com-
bines the functions of air regulation
and/or moisture and dirt removal is
recommended for most applications.
Cooling System (not shown): This
compressor contains an advanced
design cooling system. At the heart of
this cooling system is an engineered
fan. It is perfectly normal for this fan to
blow air through the vent holes in large
amounts. You know that the cooling
system is working when air is being
expelled.
Air Compressor Pump (not shown):
Compresses air into the air tank.
Working air is not available until the
compressor has raised the air tank
pressure above that required at the air
outlet.
to drain conden-
sation at the end of each use.
13 ENG 1000002023

Check Valve: When the air compres-
sor is operating, the check valve is
"open", allowing compressed air to
enter the air tank. When the air com-
pressor reaches "cut-out" pressure,
the check valve "closes", allowing air
pressure to remain inside the air tank.
Check Valve
Pressure Release Valve: The pres-
sure release valve located on the side
of the pressure switch, is designed to
automatically release compressed air
from the compressor head and the
outlet tube when the air compressor
reaches "cut-out" pressure or is shut
off. The pressure release valve allows
the motor to restart freely. When the
motor stops running, air will be heard
escaping from this valve for a few sec-
onds. No air should be heard leaking
when the motor is running or after the
unit reaches "cut-out" pressure.
Motor Overload Protector: This
motor has a manual thermal overload
protector. If the motor overheats for
any reason, the overload protector
will shut off the motor. The motor
must be allowed to cool down before
restarting. To restart:
1. Place the On/
Auto/Off
lever in the
"Off" posi-
tion.
2. Allow the
motor to
cool.
3. Depress the red reset button on
the motor.
4. Place the On/Auto/Off lever in the
"On/Auto" postion to restart the
motor.
Air Intake Filter (not shown): This
filter is designed to clean air com-
ing into the pump. This filter must
always be clean and ventilation
openings free from obstructions. See
"Maintenance".
HOW TO USE YOUR UNiT
How to Stop:
1 Set the On/Auto/Off lever to "Off"
Before Starting
_Do not operate this
unit until you read
and understand this instruction
manual for safety, operation and
maintenance instructions.
Break-in Procedure
_Risk of Property
Damage. Serious
damage may result if the following
break-in instructions are not
closely followed.
This procedure is required before the
air compressor is put into service and
when the check valve or a complete
compressor pump has been replaced.
1. Make sure the On/Auto/Off lever
is in the "Off" position.
2. Check oil level in pump. See "Oil"
paragraph in the Maintenance
section for instructions.
3. Recheck all wiring. Make sure
wires are secure at all terminals
connections. Make sure all con-
tacts move freely and are not
obstructed.
4. Open the globe valve fully to per-
mit air to escape and prevent air
pressure build up in the air tank
during the break-in period.
5. Move the On/Auto/Off lever to
"On/Auto" position. The compres-
sor will start.
6. Run the compressor for 20 min-
utes. Make sure the globe valve
is open and there is minimal air
pressure build-up in tank.
1000002023 14 ENG

7. Check all air line fittings and con-
nections/piping for air leaks by
applying a soap solution. Correct
if necessary. NOTE: Minor leaks
can cause the air compressor to
overwork, resulting in premature
breakdown or inadequate perfor-
mance.
8. Check for excessive vibration.
Readjust or shim air compressor
feet, if necessary.
9. After 20 minutes, close the globe
valve. The air receiver will fill to
"cut-out" pressure and the motor
will stop.
Before Each Start-Up:
1. Place On/Auto/Off lever to "Off".
2. Close the globe valve.
3. Attach hose and accessories.
_Risk of unsafe
operation. Firmly
grasp air hose in hand when
installing or disconnecting to
prevent hose whip.
Risk of unsafe
'"-- operation. Do not
use damaged or worn accessories.
NOTE: A regulator MUST be installed
when using accessories rated at less
than 175 PSI.
NOTE: The hose or accessory will
require a quick connect plug if the air
outlet is equipped with a quick con-
nect socket.
_Risk of Bursting.
-- Too much air
pressure causes a hazardous risk of
bursting. Check the manufacturer's
maximum pressure rating for air
tools and accessories. The regulator
outlet pressure must never exceed
the maximum pressure rating.
_Risk of unsafe
operation.
Compressed air from the unit may
contain water condensation and
oil mist. Do not spray unfiltered air
at an item that could be damaged
by moisture. Some air tools and
accessories may require filtered
air. Read the instructions for the air
tools and accessories.
How to Start:
1. Turn the On/Auto/Off lever to "On/
Auto" and allow tank pressure to
build. Motor will stop when tank
pressure reaches "cut-out" pres-
sure.
2. When the tank pressure reaches
"cut-out" pressure open the globe
valve.
iMPORTANT." When using regula-
tor and other accessories refer to the
manufacturers instructions.
if any unusual
_"__ noise or vibration
is noticed, stop the compressor
immediately and have it checked by
atrained service technician.
The compressor is ready for use.
15-ENG 1000002023

CUSTOMER RESPONSIBiLiTIES
Before Daily Every Every Every Every Yearly
each or 8 40 100 160
use after hours hours hours hours
each
use
Check Safety Valve •
Drain Tank
Oil Leaks
Check Pump Oil
Change Pump Oil
Unusual Noise and/or
Vibration
Air Filter
Drive Belt-Condition
Motor Pulley/Flywheel
alignment
Air compressor pump
intake and exhaust
valves
Inspect air lines and *
fittings for leaks
Head Bolts - Check the torques of the head bolts after the first five hours of operation.
1- more frequent in dusty or humid conditions
Risk of Unsafe
_ " '"__ Operation. Unit
cycles automatically when power
is on. When servicing, you may
be exposed to voltage sources,
compressed air, or moving parts.
Before servicing unit unplug or
disconnect electrical supply to
the air compressor, bleed tank
of pressure, and allow the air
compressor to cool.
To ensure efficient operation and lon-
ger life of the air compressor, a routine
maintenance schedule should be pre-
pared and followed. The above routine
maintenance schedule is geared to an
air compressor in a normal working
environment operating on a daily basis.
If necessary, the schedule should be
modified to suit the conditions under
which your air compressor is used.
The modifications will depend upon
the hours of operation and the work-
ing environment. Compressors in an
extremely dirty and/or hostile environ-
ment will require a greater frequency of
all maintenance checks.
1000002023 16 ENG
NOTE: See Operation section for the
location of controls.
TO CHECK SAFETY VALVE
_Bisk of Bursting.
__ If the safety valve
does not work properly, over-
pressurization may occur, causing
air tank rupture or an explosion.
_Risk from Flying
Objects. Always
wear certified safety equipment:
ANSI 2:87.1 eye protection (CAN/
CSA Z94.3) with side shields.
1. Before starting compressor, pull
the ring on the safety valve to
make sure that the safety valve
operates freely. If the valve
is stuck or does not operate
smoothly, it must be replaced
with the same type of valve.

TO DRAIN TANK
_Risk of Unsafe
Operation. Risk
from noise. Air tanks contain high
pressure air. Keep face and other
body parts away from outlet of
drain. Use ANSi Z87.1 eye protection
(CAN/CSA Z94.3) when draining as
debris can be kicked up into face.
Use ear protection (ANSi $12,6
(S3.19) hearing protection) as air flow
noise is loud when draining.
NOTE: Operation of the air compres-
sor will cause condensation to build up
in the air tank. Always drain tank on a
washable surface or in a suitable con-
tainer to prevent damaging or staining
surfaces.
1. Set the On/Auto/Off lever to "Off".
2. Close the globe valve.
3. Remove the air tool or accessory.
4. Open the globe valve and allow
the air to slowly bleed from the air
tank until tank pressure is approxi-
mately 20 PSI.
5. Close the globe valve.
6. Drain water from air tank by open-
ing drain valve on bottom of tank.
_Risk of Bursting.
Water will condense
in the air tank. if not drained, water
will corrode and weaken the air tank
causing a risk of air tank rupture.
_Risk of Property
Damage. Drain water
from air tank may contain oil and rust
which can cause stains.
7. After the water has been drained,
close the drain valve. The air com-
pressor can now be stored.
NOTE: If drain valve is plugged,
release all air pressure. The valve can
then be removed, cleaned, then rein-
stalled.
OIL
_Use air compressor
oil only. Multi-weight
automotive engine oils like 10W30
should not be use in air compressors.
They leave carbon deposits on
critical components, thus reducing
performance and compressor life.
NOTE: Use 30W compressor oil or a
heavy duty SAE 30W, non-detergent,
SF grade or better oil DO NOT use
multi-weight automotive engine oils,
they will reduce compressor life. Under
extreme winter condition use SAE-10
weight oil.
NOTE: Crankcase oil capacity is
approximately 48 fluid ounces (1.4 L).
Checking
1. The oil level should be to the
middle of the sight glass (C).
2. If needed remove oil fill plug (A)
and slowly add oil until it reaches
the middle of the sight glass.
Changing
1. Remove the oil fill plug (A).
2. Remove the oil drain plug (B) and
drain oil into a suitable container.
3. Replace the oil drain plug (B) and
tighten securely.
4. Slowly add compressor oil until
the oil level is in the middle of the
sightglass (C). NOTE: When filling
the crankcase, the oil flows very
slowly into the pump. If the oil is
added too quickly, it will overflow
and appear to be full.
_Risk of Unsafe
Operation. Overfilling
with oil will cause premature
compressor failure. Do not overfill.
5. Replace oil fill plug (A) and tighten
securely.
17 ENG 1000002023

AiR FILTER - iNSPECTiON AND
REPLACEMENT
_Hot surfaces.
Risk of burn.
Compressor heads are exposed
when filter cover is removed.
Allow compressor to cool prior to
servicing.
_Keep the air filter
clean at all times. Do
not operate the air compressor with
the air filter removed.
A dirty air filter will not allow the com-
pressor to operate at full capacity.
Keep the air filter clean at all times.
1. Remove air filter.
2. Remove the air filter cover.
3. Remove the air filter from filter
cover.
IMPORTANT: Do not operate the com-
pressor with the air filter removed.
4. Place new air filter into filter cover.
Refer to the Repair Parts for the
correct part number.
5. Replace air filter cover and reas-
semble air filter to pump.
BELT = REPLACEMENT
(Refer to the Parts List for
replacement belt part number.)
Serious injury or
""__ damage may occur
if parts of the body or loose items
get caught in moving parts. Never
operate the outfit with the belt guard
removed. The belt guard should
be removed only when the air
compressor power is disconnected.
1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Remove the belt guard.
3. Mark pump position on saddle.
4. Loosen the motor mounting
screws and slide the motor
toward the air compressor.
5. Remove the belt and replace with
a new one.
Risk of moving
""__ parts. Use caution
when roiling belt onto flywheel,
fingers can get caught between the
belt and flywheel.
1000002023
6. See the "Adjust Belt Tension"
before tightening motor mounting
screws.
ADJUSTING BELT TENSION
1. Slide motor into original position,
line the motor up with the mark
made earlier on saddle.
2. Tighten two outside motor mount-
ing screws enough to hold the
motor in place for checking pulley
and flywheel alignment.
3. The belt should deflect 3/16"
(4.8 mm) at midway between the
pulley and the flywheel when a
5-10 pound weight is applied at
the midway point.
3. When proper belt tension is
achieved, tighten all four motor
mounting screws. See Parts list
for torque specifications.
NOTE: Once the engine pulley has
been moved from its factory set loca-
tion, the grooves of the flywheel and
pulley must be aligned to within 1/16"
(1.6 ram) to prevent excessive belt
wear. Verify the alignment by perform-
ing the following Pulley and Flywheel
- Alignment.
MOTOR PULLEY/FLYWHEEL
ALIGNMENT
NOTE: Once the motor pulley has
been moved from its factory set loca-
tion, the grooves of the flywheel and
pulley must be aligned to within 1/16"
(1.6 mm) to prevent excessive belt
wear.
The air compressor flywheel and motor
pulley must be in-line (in the same
plane) within 1/16" (1.6 mm) to assure
belt retention within flywheel belt
grooves. To check alignment, perform
the following steps:
18 ENG

1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Remove belt guard.
3. Place a straightedge against the
outside of the flywheel and the
motor drive pulley.
4. Measure the distance between
the edge of the belt and the
straightedge at points A1 and A2
in figure. The difference between
measurements should be no more
than 1/16" (1.6 mm).
5. If the difference is greater than
1/16" (1.6 mm) loosen the set
screw holding the motor drive
pulley to the shaft and adjust the
pulley's position on the shaft until
the A1 and A2 measurements
are within 1/16" (1.6 mm) of each
other.
6. Tighten the motor drive pulley
set screw. See Parts manual for
torque specifications.
7. Visually inspect the motor drive
pulley to verify that it is perpen-
dicular to the drive motor shaft.
Points B1 and B2 of Figure
should appear to be equal. If
they are not, loosen the setscrew
of the motor drive pulley and
equalize B1 and B2, using care
not to disturb the belt alignment
performed in step 2.
8. Retighten the motor drive pulley
setscrew. See Parts manual for
torque specifications.
9. Reinstall belt guard.
AIR COMPRESSOR PUMP
iNTAKE AND EXHAUST VALVES
Once a year have a Trained Service
Technician check the air compressor
pump intake and exhaust valves.
iNSPECT AIR LINES AND
FITTINGS FOR LEAKS
1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Apply a soap solution to all air line
fittings and connections/piping.
3. Correct any leaks found.
IMPORTANT: Even minor leaks can
cause the air compressor to overwork,
resulting in premature breakdown or
inadequate performance.
AIR COMPRESSOR HEAD
BOLTS =TORQUING
The air compressor pump head bolts
should be kept properly torqued.
Check the torques of the head bolts
after the first five hours of operation.
Retighten if necessary. See Parts List
for torque specifications.
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE
PERFORMED BY TRAINED SERVICE TECHNICIAN.
_Risk of Unsafe
Operation. Unit
cycles automatically when power
is on. When servicing, you may
be exposed to voltage sources,
compressed air, or moving parts.
Before servicing unit unplug or
disconnect electrical supply to
the air compressor, bleed tank
of pressure, and allow the air
compressor to cool.
TO REPLACE OR CLEAN CHECK
VALVE
1. Release all air pressure from air
tank. See "To Drain Tank" in the
Maintenance section.
2. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
3. Using an adjustable wrench loos-
en outlet tube nut at air tank and
pump. Carefully move outlet tube
away from check valve.
100000202319 ENG

4. Using an adjustable wrench
loosen pressure relief tube nut
at air tank and pressure switch.
Carefully move pressure relief tube
away from check valve.
5. Unscrew the check valve (turn
counterclockwise) using a 7/8"
open end wrench. NOTE the ori-
entation for reassembly.
6. Using a screwdriver, carefully
push the valve disc up and down.
NOTE: The valve disc should
move freely up and down on a
spring which holds the valve disc
in the closed position, if not the
check valve needs to be cleaned
or replaced.
position
nothing is
visible.
In closed position
disc is visible,
7. Clean or replace the check valve.
A solvent, such as paint or varnish
remover can be used to clean the
check valve.
8. Apply sealant to the check valve
threads. Reinstall the check valve
(turn clockwise).
9. Replace the pressure release tube.
Tighten nuts.
10. Replace the outlet tube and tight-
en nuts.
11. Perform the Break-in Procedure.
See "Break-in Procedure" in the
Operation section.
ADDiTiONAL SERVICE
Disassembly or service of the air
compressor beyond what is covered
in this manual is not recommended.
If additional service is required, con-
tact your nearest Authorized Warranty
Service Center.
Before you store the air compressor,
make sure you do the following:
1. Review the Maintenance section
on the preceding pages and per-
form scheduled maintenance as
necessary.
2. Set the On/Auto/Off lever to "Off".
3. Close the globe valve.
4. Remove the air tool or accessory.
5. Open the globe valve and allow
the air to slowly bleed from the air
tank until tank pressure is approxi-
mately 20 PSI.
6. Drain water from air tank by open-
ing drain valve on bottom of tank.
_ Water will condense
in the air tank. if
not drained, water will corrode and
weaken the air tank causing a risk
of air tank rupture.
7. After the water has been drained,
close the drain or drain valve.
NOTE: If drain valve is plugged,
release all air pressure. The valve can
then be removed, cleaned, then rein-
stalled.
8. Protect the air hose from damage
(such as being stepped on or run
over).
1000002023 20 ENG