Craftsman 919.165612 User manual

Owner's Manual
iCRHFTSMRN'i
Permanently Lubricated
Twin V
2-Stage
Stationary
AIR COMPRESSOR
Model No.
919.165612
•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
D30088 Rev. 0 9/26/03

WARRANTY ................................................ 2
SPECIFICATION CHART ..................................... 3
SAFETY GUIDELINES-DEFINITIONS ........................... 3
IMPORTANT SAFETY INSTRUCTIONS ........................ 3-8
GLOSSARY ................................................ 9
ACCESSORIES ............................................. 9
DUTY CYCLE .............................................. 9
ASSEMBLY ............................................... 10
INSTALLATION .......................................... 10-12
OPERATION ............................................ 13-15
MAINTENANCE ......................................... 16-17
SERVICE AND ADJUSTMENTS ............................... 18
STORAGE ................................................ 19
TROUBLESHOOTING GUIDE .............................. 20-22
REPAIR PARTS ......................................... 23-27
REPAIR PROTECTION AGREEMENTS ......................... 51
HOW TO ORDER REPAIR PARTS ............................. 28
FULL ONE YEAR WARRANTY AIR COMPRESSOR
If this CRAFTSMAN Air Compressor 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 your nearest Sears Service
Center (1-800-4-MY-HOME ®)to arrange for repair, or return the Air
Compressor to the place of purchase for replacement.
If this Air Compressor is used for commercial or rental purposes, this warrant
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
D30088 2* ENG

-1_ =let I_1[e_,__lII[o]_I[e_-"F__:tl
Model No. 919.165612
Max. Developed HP 7
Running HP 2.9
Bore 2.375
Stroke-High Pressure .54"
Low Pressure 1.45"
Voltage-Single Phase 240/60/1
Minimum Branch Circuit Requirement 15 amps
Fuse Type Time Delay
Air Tank Capacity - Gallons 60
Approximate Cut-in Pressure 145
Approximate Cut-out Pressure 175
SCFM@40 psig 9.6
SCFM@90 psig 9.0
Referto Glossary for abbreviations
[.'-Yz1_l_l_'l_tl]lm]=lll#l=B-]. Im]=l_ll#lbll[o_]_:-]
This manual contains information that iS important for you to know and understand. 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 sections.
_'_ Indicates an
imminently hazardous
situation which, if not avoided, will
result in death or serious injurv.
_lndicates a potentially
hazardous situation
which, if not avoided, could result in
death or serious injury.
_lndicates a potentially
hazardous situation
which, if not avoided, _ result in
minor or moderate injury.
_"_lUsed without the
safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may
result in oroDertv damaae.
Ih_l_o]-'tpL+_+hnl£:'/.,_al_S'd_[IP.[-:-]ljt,ttl_o,]njl[o_]P.[-.+
SAVE THESE INSTRUCTIONS
IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULTIN
SERIOUS INJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL
WARNINGSAND OPERATINGINSTRUCTIONSBEFOREUSING THIS EQUIPMENT.
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
•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 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.
3* ENG D30088

II_ I_o] ;111P'.'q+IInl[,.'9'.,__1_ &'i __JL_[,._)III,_]LI_+']IIT[_o_+]L_,[,._
Save these instructions
Improper operation or maintenance of this product could result in serious injury and
property damage. Read and understand all warnings and operation instructions before
using this equipment,
,l;1"l'J "-In
WARNING: Risk of explosion or fire
What Could Happen How To Prevent It
It is normal for electrical contacts Always operate the compressor in a well
within the motor and pressure switch to ventilated area free of combustible
spark, materials, gasoline, or solvent vapors.
If electrical sparks from compressor If spraying flammable materials, locate
come into contact with flammable compressor at least 20 feet away from
vapors, they may ignite, causing fire or spray area. An additional length of hose
explosion, may be required,
Store flammable materials in a secure
location away from compressor.
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.
Never place objects against or on top
of compressor. Operate compressor in
an open area at least 12 inches away
from any wall or obstruction that would
restrict the flow of fresh air to the
ventilation openings.
Operate compressor in a clean, dry wall
ventilated area. Do not operate unit
indoors or in any confined area.
Always remain in attendance with the
)roduct when it is operating.
Always disconnect electrical power by
moving pressure switch lever to the off
}osition and drain tank daily or after
each use.
D30088 4* ENG

WARNING: Risk of Bursting
Air Tank: The following conditions could lead to a weakening of the tank, and result
in a violent tank explosion and could cause property damage or serious injury,
What Could Haopen How To Prevent It
Failure to properly drain condensed Drain tank daily or after each use. If
water from tank, causing rust and tank develops a leak, replace it
thinning of the steel tank. immediately with a new tank or replace
the entire compressor.
Modifications or attempted repairs to Never drill into, weld, or make any
the tank. modifications to the tank or its
Unauthorized modifications to the attachments.
unloader valve, safety valve, or any
other components which control tank
pressure.
Excessive vibration can weaken the The tank is designed to withstand specific
air tank and cause rupture or operating pressures. Never make
explosion adjustments or parts substitutions to
alter the factory set operating
pressures=
ATTACHMENTS & ACCESSORIES:
Exceeding the pressure rating of air
tools, spray guns, air operated
accessories, tires, and other inflatables
can cause them to explode or fly apart,
and could result in serious injury.
For essential control of air pressure, you
must install a pressure regulator and
pressure gauge to the air outlet (if not
equipped) of your compressor. 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.
WARNING: Risk from Flying Objects
What Could Happen How To Prevent It
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.
Always wear ANSI Z87.1 approved safety
glasses with side shields when using the
compressor.
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 tank
before attempting maintenance, attaching
to0_s Oi" accessories,
5* ENG D30088

:f:1"4_;ll
WARNING: Risk of Electrical Shock
What Could 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.
See grounding instructions,
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.
WARNING: Risk of Breathing
What Could Happen How To Prevent It
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 tank. Breathing these
contaminants can cause serious injury
or death.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides,
weed killers, may contain harmful
vapors and poisons,
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. Use a NtOSH/MSHA
approved respirator designed for use with
your specific application.
D30088 6* ENG

WARNING: Risk of Burns
What Could Happen
Touching exposed metal such as the
compressor head or outlet tubes, can
result in serious burns.
How To Prevent It
Never touch any exposed metal parts
on compressor during or immediately
after operation. Compressor will remain
hot for several minutes after operation.
Do not reach around protective shrouds
or attempt maintenance until unit has
been allowed to cool.
;f.,v#.,1"1=
WARNING: Risk from Moving Parts _)
What Could Happen How To Prevent It
Moving parts such as the pulley, flywheel, Never operate the compressor with
and belt can cause serious injury if they guards or covers which are damaged or
come into contact with you or your removed.
clothing.
Attempting to operate compressor with Any repairs required on this product
damaged or missing parts or attempting should be performed by authorized
to repair compressor with protective service center personnel.
shrouds removed can expose you to
moving parts and can result in serious
injury,
;f.,VN.,I"1=
WARNING: Risk of Falling
What Could Happen
A portable compressor can fall from a
table, workbench, or roof causing
damage to the compressor and could
result in serious injury or death to the
operator.
How To Prevent It
Always operate compressor in astable
secure position to prevent accidental
movement of the unit. Never operate
compressor on eroof or other elevated
position. Use additional air hose to
reach high locations.
7÷ ENG D30088

WARNING: Risk of Serious Injury or Property Damage When
Transporting Compressor
(Fire, Inhalation, Damage to VehicleSurfaces)
What Could Happen How To Prevent It
Oil can leak or spill and could result in Always place COMPRESSOR on a
fire or breathing hazard; serious injury or protective mat when transporting to
death can result, oil leaks will damage protect against damage to vehicle from
carpet, paint or other surfaces in leaks. Remove COMPRESSOR from
vehicles or trailers, vehicle immediately upon arrival at your
destination.
WARNING: Risk of Unsafe Operation _1=
What Could Happen How To Prevent It
Unsafe operation of your air compressor
could lead to serious injury or death to
you or others.
Review and understand all instructions
and warnings in this 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 a fire
extinguisher.
DO not operate machine with missing,
broken, or unauthorized parts.
SAVE THESE INSTRUCTIONS
D30088 8* ENG

Become familiar with these terms
before operating the unit.
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per
minute; aunit 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
automatically. 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
automatically 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
electricity from electrical panel to
outlet.
The accessories and tools 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.
mL__luJnkTd[e,_ q=1
This air compressor pump is capable
of running continuously. However, to
prolong the life of your air
compressor, it is recommended that a
50%-75% average duty cycle be
maintained; that is, the air
compressor pump should not run
more than 30-45 minutes in any given
hour.
9- ENG D30088

Contents of Carton
1 - Air Compressor
1 - Parts bag containing:
1 - Operator's Manual
1 - Parts Manual
4- 5/8" Washers
Tools Required for Assembly
1 - 9/16" socket or open end wrench
Electric drill
Unpacking
1. Remove all packaging.
Risk of Unsafe
Opertation. It may
be necessary to brace or support
one side of the unit 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.
II__.']1L,III Ir.,tiI[o_
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" 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 electrical
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
compressor.
Anchoring of the Air
Compressor
IF_qPJI_'R_I Risk of Unsafe
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
4 - 3/8" Lag screw to fit
concrete anchors (not
supplied)
4 - 5/8" Washer (found in parts
bag) shims (if needed)
1. Place the air compressor on 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.
j13/8" Lag
./Screw
5/8" Washer _/_(not supplied)
(supplied) iI _ _
_Surface Line
Shim Under
Washer Concrete Anchor
(not supplied) (not supplied)
4. Line-up holes in surface with
holes in air compressor feet.
D30088 10_ ENG

5. Place the (4) washers (supplied)
between the floor and air
compressor feet. If needed, solid
shims may be placed between
the washers and floor to evenly
distribute weight on all four feet.
See next figure.
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
electrical 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
nameplate, 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 overheating 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. Risk of Unsafe
Operation, Certain
air compressors can be operated
on a 15 amp circuit if the following
conditions are met.
1. Voltage supply to circuit must
comply with the National
Electrical Code.
2. Circuit is not used to supply any
other electrical needs.
3. Extension cords comply with
specifications.
4. Circuit is equipped with a 15
amp circuit breaker or 15 amp
time delay fuse. NOTE: If
compressor is connected to a
circuit protected by fuses, use
only time delay fuses. Time delay
fuses should be marked "D" in
Canada and "T" in the US.
If any of the above conditions cannot
be met, or if operation of the
compressor repeatedly causes
interruption of the power, it may be
necessary to operate it from a 20
amp circuit. It is not necessary to
change the cord set.
Air Distribution System
Risk of Unsafe
Operation. 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.
11_ENG D30088

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 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
recommended to be installed
between the air discharge outlet
and main air distribution line to
allow for vibration.
A separate regulator is
recommended to control the air
pressure. Air pressure from the
tank is usually to high for
individual air driven tools.
FEEDER UN_S SLOPE
AIR FLOW _WITH AIR FLOW
MAIN I_STRt BUTION A_R LINES
S_ope pipe in direction of air f_ow.
Water condensate flows a_ng
_botmm of pipe to drain legs,
preven_ng r; from entering feeder
_ines.
LUBRICATOR
DP_N _
TRAP
_MO_URE
SEPARATOR
AND TRAP
LEG
AIR DISCI-I,_G E /
VALVE
TYPICAL COMPRESSED
AIR DISTRIBUTION SYSTEM
DRAIN COCK
VALVE _
A_R
COMPRESSOR
D30088 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
reference.
Description of Operation
Become familiar with these controls
before operating the unit.
Tank
Pressure Gauge
On/Auto/Off Switch: Turn this switch
ON 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" pressure.
Safety Valve: If the 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
factory set pressure (slightly higher
than the pressure switch "cut-out"
setting). 13_ENG
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.
Drain Valve: The drain valve is
located at the base of the air tank
and is used to drain condensation at
the end of each use.
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.
D30088

Check Valve: When the air
compressor is operating, the check
valve is "open", allowing compressed
air to enter the air tank. When the air
compressor reaches "cut-out"
pressure, the check valve "closes",
allowing air pressure to remain inside
the air tank.
Pressure Release Valve: The
pressure 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 afew seconds. No
air should be heard leaking when the
motor is running, or continuous
leaking after unit reaches "cut-out"
pressure.
Pressure
Release
Valve
Air Intake Filter (not shown) This
filter is designed to clean air coming
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 leverto
"OFF".
Before Starting
Break-in Procedure
Risk of Unsafe
Operation. 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. Recheck all wiring. Make sure
wires are secure at all terminals
connections. Make sure all
contacts move freely and are not
obstructed.
3. Open the globe valve fully to
permit air to escape and prevent
air pressure build up in the air
tank during the break-in period.
4. Move the On/Auto/Off lever to
"ON/AUTO" position. The
compressor will starL
5. Run the compressor for 15
minutes. Make sure the globe
valve is open and there is
minimal air pressure build-up in
tank.
6. Check all air line fittings and
connections/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 performance.
D30088 14_ ENG

7. Check for excessive vibration.
Readjust or shim air compressor
feet, if necessary.
8. After 15 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.
NOTE: A regulator MUST be
installed when using accessories
rated at less than 175 PSI
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.
How to Start
1. Turn the On/Auto/Off lever to
"AUTO" and allow tank pressure
to build. Motor will stop when
tank pressure reaches "cut-out"
pressure.
2. When the tank pressure reaches
"cut-out" pressure open the
globe valve.
IMPORTANT: When using regulator
and other accessories refer to the
manufacture instructions.
15_ ENG D30088

Customer Responsibilities
Check Safety Valve
Drain Tank
Air Filter
Inspect air lines and fittings
for leaks
Air compressor pump intake
and exhaust valves
Before Daily ol
after Every
aach each 40 Frequently
use use hours
1
Yearly
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
longer life of the air compressor, a
routine maintenance schedule should
be prepared and followed. The
following routine maintenance
schedule is geared to an unit in a
normal working environment
operating on a daily basis. If
necessary, the schedule should be
modified to suit the conditions under
which your compressor is used. The
modifications will depend upon the
hours of operation and the working
environment. Compressors in an
extremely dirty and/or hostile
environment will require a greater
frequency of all maintenance checks.
NOTE: See "Operation" section for
the location of controls.
To Check Safety Valve
Risk of Bursting. If
the safety valve
does not work properly, over-
pressurization may occur, causing
air tank rupture or an explosion.
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
1. Set the On/Auto/Off lever to
"OFF" and disconnect electrical
supply.
2. Pull the regulator knob out and
turn clockwise to set the outlet
pressure to zero.
3. Remove the air tool or
accessory.
4. Pull ring on safety valve allowing
air to bleed from the tank until
tank pressure is approximately
20 psi. Release safety valve ring.
5. Drain water from air tank by
opening drain valve (counter-
clockwise) on bottom of tank.
D30088 16_ ENG

I_ 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.
6. After the water has been drained,
close the drain valve (clockwise).
The air compressor can now be
stored.
NOTE: If drain valve is plugged,
release all air pressure. The valve
can then be removed, cleaned, and
reinstalled.
Air Filter - Inspection and
Replacement
Risk of Burns.
Compressor head
and cylinder sleeve are very hot.
Do not touch. Allow compressor to
cool prior to servicing.
A dirty air filter will not allow the
compressor to operate at full
capacity. Keep the air filter clean at
all times.
1. Remove the air filter cover.
Air Filter
Air Filter
2. Remove the air filter and make
sure it is clean.
IMPORTANT: Do not operate the
compressor with the air filter
removed.
3. If dirty, rinse air filter with warm
water and squeeze dry.
4. Replace air filter and air filter
cover.
NOTE: If the air filter is extremely
dirty it will need to be replaced. Refer
to the "Repair Parts" for the correct
part number.
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 the air compressor on to
inspect for air leaks.
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.
MoOr
The motor has an automatic reset
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. The
compressor will automatically restart
after the motor cools.
if the overload protector shuts the
motor off frequently, check for a
possible voltage problem. Low
voltage can also be suspected when:
1. The motor does not get up to full
power or speed.
2. Fuses blow out when starting
the motor; lights dim and remain
dim when motor is started and is
running.
17_ ENG D30088

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. Set the On/Auto/Off lever to
"OFF" and disconnect electrical
supply
3. Using a phillips screwdriver
remove the air filter cover.
4. Remove the rear shrouds using
T-20 torx wrench.
5. Using an adjustable wrench
loosen outlet tube nut at air tank.
Carefully move outlet tube away
from check valve.
6. Using an adjustable wrench
loosen pressure relief tube nut at
air tank. Carefully move pressure
relief tube away from check
valve.
Outlet Tube
7.
8.
Unscrew the check valve (turn
counterclockwise) using a 7/8"
open end wrench. Note the
orientation for reassembly.
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.
open
position
nothing is
visible.
tn closed position
disc is visible.
9. Clean or replace the check valve.
A solvent, such as paint or
varnish remover can be used to
clean the check valve.
10. Apply sealant to the check valve
threads. Reinstall the check valve
(turn clockwise).
11. Replace the pressure release
tube. Tighten nut.
12. Replace the outlet tube and
tighten nut.
13. Replace the shroud and air filter.
14. Perform the Break-in Procedure.
See "Break-in Procedure" in the
Operation section.
D30088 18_ ENG

Before you store the air compressor,
make sure you do the following:
1. Review the "Maintenance"
section on the preceding pages
and perform scheduled
maintenance as necessary.
2. Set the On/Auto/Off lever to
"OFF" and disconnect electrical
supply
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
approximately 20 psi.
6. Drain water from air tank by
opening drain valve (counter-
clockwise) 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 arisk
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
reinstalled.
8. Protect the air hose from
damage (such as being stepped
on or run over).
19_ ENG D30088

d:{ollJ :] il ::F,."]-"[oIo]l III_[I
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.
PROBLEM CORRECTION
Excessive tank
pressure - safet
valve pops off.
Air leaks at
fittings.
Air leaks at or
inside check
valve
CAUSE
Pressure switch does not
shut off motor when
compressor reaches "cut-
out" pressure.
Pressure switch "cut-out"
too high.
Tube fittings are not tight
enough.
Check valve seat damaged.
Move On/Auto/Off lever to
the "OFF" position, if the
unit does not shut off contact
a Trained Service Technician.
Contact a Trained Service
Technician.
Tighten fittings where air can
be heard escaping. Check
fittings with soapy water
solution. Do Not
Overti_hten.
A defective check valve
results in aconstant air leak
at the pressure release valve
when there is pressure in the
tank and the compressor is
shut off. Replace check
valve. Refer the "To Replace
or Clean Check Valve" in the
"Service and Adjustment"
section.
Air leaks at Defective pressure switch Contact a Trained Service
pressure switch release valve. Technician.
release valve.
Defective air tank.
Air leaks in air
tank or at air
tank welds.
Air tank must be replaced.
Do not repair the leak.
Risk of
Bursting.
Do not drill into, weld or
otherwise modify air tank
or it will weaken. The tank
can rupture or explode.
Air leaks Leaking seal. Contact a Trained Service
between head Technician.
and valve plate.
D30088 20_ENG