Craftsman 919.165613 User manual

N004083
Owner's Manual
Permanently Lubricated
Twin V
2-Stage
Stationary
AIR COMPRESSOR
Model No.
919.165613
• 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: ,,Arww.sears.com/craftsman
N004083 Revo o41_4!08

W$.RRANTY ................................................ 2
SPECIFICATION CHART ..................................... 3
SAFETY GUIDELINES-DEFINITIONS ........................... 3
IMPORTANT SAFETY' INSTRUCTIONS ........................ 3-8
GLOSSARY ................................................ 9
ACCESSORIES ............................................. 9
DUTY CYCLE .............................................. 9
ASSEMBLY ............................................... I0
INSTALLATION ......................................... 10-I 2
OPERATION ........................................... 13-I 5
MAINTENANCE ......................................... 16-18
SERVICE AND ADJUSTMENTS ............................... 18
STORAGE ................................................ 19
TROUBLESHOOTING GUIDE ............................. 20-22
REPAIR PARTS 24-27
REPAIR PROTECTION AGREEMENTS 49
HOW TO ORDER REPAIR PARTS ...................... Back Cover
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 (ib) 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 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
N004083 2- ENG

Model No.
Run'n_ng HP
Bore
Stroke-High Pressure
Low Pressure
Voltage-Single Phase
Minimum Branch Circuit Requirement
Fuse Type
Air Tank Capacity - Gallons
Approximate Cut-in Pressure
Approximate Cut-out Pressure
SCFM@ 40 psig
SCFM@ 90 #sig
919.165613
*2.9
2.375
.54"
1.45"
240/60/1
15 amps
Time Delay
60
145
175
*9.6
*9.0
* Tested per lSO 1217
Refer to Glossary for abbreviations.
This manual contains information that is important for you to know and under-
stand. This information relates to protecting YOUR SAFE'rY 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, will
result in death or serious injury.
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
_n properbj damage.
This product contains chemicals known to the State of
California to cause cancer, and birth defects or other reproductive harm.
Wash hands after handling.
Some dust contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm such as
asbestos and lead in lead based paint.
To reduce the risk of injury, read the instruction manual .1_L_I
SAVE THESE INSTRUCTIONS
3- ENG N004083

WHAT CAN HAPPEN
° It is normal for electrical contacts
within the motor and pressure
switch to spark.
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.
RISK OF F._XPLOSION OR FIRE
HOW TO PREVENT IT
Always operate the compressor
in a well ventilated area free of
combustible materials, gasoline, or
solvent vapors.
° If spraying flammable materials, locate
compressor at least 20 feet (6.1 m)
away from spray area. An additional
length of air hose may be required.
o 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.
Store unit indoors.
- Always remain in attendance with
the product when it is operating.
° Disconnect electrical supply when
not in use.
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.
RISK TO BREATHING (ASPHYXIATION)
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.
N004083 4- ENG

.Exposure to chemicals in dust creat-
ed by power sanding, sawing, grind-
rag, drilling, and other Construction
activities may be harmful.
• Sprayed materials such as paint,
paint solvents, paint remover, insec-
ticides, weed killers, may contain
harmful vapors and poisons.
Work in an area with good cross
ventilation. Read and follow the safe-
ty instructions provided on the label
or safety data sheets for the materi-
als you are spraying. Always use
certified safety equipment: NIOSH/
OSHA respiratory protection or prop-
erly fitting face mask designed for
use with your specific application.
__ 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. To find 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
inflatables can cause them to
explode or fly apart, and could result
in serious injury.
HOW TO PREVENT IT
Drain air tank daily or after each use.
if air 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 N004083

_j_ RISK OF ELECTRICAL SHOCK
o •
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
personr{el 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.
__ 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
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 air tank before attempting
maintenance, attaching tools or
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.
N004083 6- ENG

WHAT CAN HAPPEN
• Touching exposed metal such as
the compressor head, engine head,
engine exhaust or outlet tubes, can
result in serious burns.
RISK OF HOT SURFACES 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.
FROMMOVINGPA.TS
o o
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.
At-tempting 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 inju_.
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 N004083

R SKOFUNSAFE
WHAT CAN HAPPEN
o •
Unsafe operation of your air
compressor could lead to serious
injury or death to you or others.
OPERATION
HOW TO PREVENT IT
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.
j__ RISK OF INJURY FROM LIFTING
WHAT CAN HAPPEN I
°Serious injury can result from i"
attempting to lift too heavy an
object.
HOW TO PREVENT IT
The compressor is too heavy to
be lifted by one person. Obtain
assistance from others before lifting.
__ RISK FROM NOISE
WHAT CAN HAPPEN 1
•Under some conditions and duration 1=
of use, noise from this product may
contribute to heafinq toss.
HOW TO PREVENT IT
Always wear certified safety equipment:
ANSt S12.6 ($3.19) hearing protection.
SAVE THESE INSTRUCTIONS
N004083 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.
PSIG: 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 evatdated 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 acces-
sory. When the tank pressure drops
to a certain low level the motor will
restart automatically. The low pres-
sure at which the motor automatically
restarts is called "cutqn" 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.
The accessories and tools are avail-
able 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)
o 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.
This air compressor pump is capable
of running continuously. However,
to prolong the life of your air com-
pressor, it is recommended that a
50%-75% average duty cycle be
maintained; that is, the air compres-
sor pump should not run more than
30-45 minutes in any given hour.
9- ENG N004083

Contents of Carton
1 - Air Compressor
1 - Parts bag containing:
1 - Operator's Manuat
1 - Parts Manual
4- 5/8" Washers
Tools Required for Assembly
1 - 9/16" socket or open end
wrench
1 - Electric drill
Unpacking
1, Remove all packaging.
HOW TO SET UP YOUR UNIT
Risk of Unsafe
Opertation. it may
be necessary to brace or support
one side of the unit when removing
the pallet because the air compres-
sor will have a tendency
to tip.
2. Remove and discard the (4)
screws and washers holding the
compressor to the palfet.
,With the help of another person
carefully remove air compressor
from pallet and place on a level
surface.
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 sup-
ply as possible to avoid using
long lengths of electrical wiring.
NOTE: Long lengths of electrical
wiring could cause power toss 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
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)
!. 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.
N004083 t0-ENG

I
.........3/8" Lag
...._ ...........Screw
,, ..............__ (not supplied)
5/8 Washer .........
(supplied) i _[-_
.... I ......
Shim Und_er _Surf_ace Line
Washer Concrete Anchor
(not 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
Improper electrical
installation of this
product may void its warranty and
your fire insurance. Have circuit wiring
performed by qualified personnel
such as a licensed electricians who
is familiar with the current national
electrical code and any prevailing local
electrical codes. Une mauvaise
connexion 6tectrique de ce produit
pourrait annuler la garantie et votre
assurance contre les incendies.
A qualified electrician needs to knows
the following before wiring:
t. 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. 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 acircuit protect-
ed 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 com-
pressor 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 Bursting.
Plastic or PMC
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.
11- ENG N004083

The next figure represents a typical
air distribution system. The following
a_ips 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.
,, Bur,/underground lines below
the frost line and avoid pockets
p
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.
FEEDER LINES SLOPE ./"--"-.
r_LJ _ _ _,_ , LUBRICATOR
4
[I MOISTURE ______
t l S_LEXIBLE i__
.... AIRD,SO.AR E
TYPICAL COMPRESSED
AIR DiSTRiBUTION SYSTEM
AIR
COMPRESSOR
DRAIN COCK
VALVE
N004083 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.
On/Auto(I)/
off(o)
On/Auto(I)/Off(O) Switch: Turn this
switch "On!Auto(t)" to provide auto-
matic power to the pressure switch and
"Off(O)" 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" pres-
sure. tt 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 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 c!ockwise to
close.
Drain Valve: The drain valve is locat-
ed at the base of the air tank and is
used to drain condensation at the
end of each use.
Drain
Valve
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.
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.
13- ENG N004083

Pressure Release Valve: The
pressure release valve, located on
the-_de of the pressure switch, is
designed to automatically release
compressed air from the compres-
sor 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 seconds.
No air should be heard leaking when
the motor i;s running, or continuous
leaking after unit reaches "cut-out"
pressu re.
Motor Overload Protector (not
shown): The motor has an automatic
reset thermal overload protector. If
the motor overheats for any reason,
the overtoad protector will shut off the
motor. The motor must be allowed
to cool down before restarting. The
compressor wilt automatically restart
after the motor cools.
Air Intake Filter (not shown) This
filter is designed to clean air coming
into the This filter must always
be clean pump ventilationand openings free
from obstructions. See Maintenance.
HOW TO USE YOUR UNLIT
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
,_,o,, 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. Recheck all wiring. Make sure
wires are secure at all terminals
connections. Make sure all con-
tacts move freely and are not
obstructed.
3. 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.
4. Move the On/Auto/Off lever to
"On!Auto" position. The compres-
sor will start,
5. Run the compressor for 15 min-
utes. Make sure the globe valve
is open and there is minimal air
pressure build-up in tank.
6. 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.
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 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.
N004083 14- ENG

NOTE: The hose or accessory will
require a quick connect plug if the air
ou_Lgt is equipped with a quick con-
nect socket.
Risk of Bursting.
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
a trained service technician,
The compressor is ready for use.
15- ENG N004083

CUSTOMER RESPONSIBILITIES
Before
each use
X
Daily or after
each use
Check Safety Valve
Drain Tank X
Air Filter
Air compressor pump
intake and exhaust
valves
Inspect air lines and X
fitt!ngs for_ leaks
j_ more frequent in dusty or humid conditions
Every 40 hours
X1 ....
Yearly
X
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 schedute 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 maihtenance 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.
Risk from Flying
Objects. Always
wear certified safety equipment:
ANSI Z87.1 eye protection (CAN/
CSA Z94.3) with side shields.
,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
($3.19) 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 toot or accessory.
N004083 16- ENG

4. Open the globe valve and allow
the air to slowly bleed from the
-'_air tank until tank pressure is
approximately 20 psi.
5. Close the globe valve.
6. Drain water from air tank by
opening 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
compressor can now be stored.
NOTE: If drain valve is plugged,
release all air pressure. The valve
can then be removed, cleaned, then
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 wil! not allow the
compressor to operate at full capacity.
Keep the air filter clean at all times.
1. Remove the air filter cover.
2. Remove the air filter and make
sure it is clean.
Air Filter
Cover
IMPORTANT: Do not operate
the compressor with the air filter
removed.
.
.
If dirty, rinse air filter with warm
water and squeeze dry'.
Replace air filter and air filter
cover.
NOTE: tf the air filter is extremely
dirty it wilt 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 over-
work, resulting in premature break-
down or inadequate performance.
17- ENG N004083

ALL MAINTENANCE AND REPAIR
OPERATIONS NOT LISTED MUST
BE PERFORMED BY TRAINED
SERVICE TECHNICIAN.
.Remove the rear shrouds using
"1"-20torx wrench.
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.
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 pres-
sure relief tube away from check
valve.
.Unscrew the check valve (turn
counterclockwise) using a 7/8"
open end wrench. Note the ori-
entation for reassembly.
N004083 18- ENG

8. Using a screwdriver, care-
fully 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.
r
position
nothing is
visible.
In closed position
disc is visible.
9. Clean or replace the check valve.
A solvent, such as paint or var-
nish 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 tight-
en nut.
13. Replace the shroud and air filter.
14. Perform the Break-in Procedure.
See Break-in Procedure in the
Operation section.
Before you store the air compressor,
make sure you do the following:
I. Review the Maintenance section
on the preceding pages and per-
form 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 alfow
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 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
reinstalled.
8. Protect the air hose from dam-
age (such as being stepped on
or run over).
19- ENG N004083

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
Excessive tank
pressure - safety
valve pops off.
Air leaks at
fittings.
Air leaks at or
inside check
valve
CAUSE CORRECTION
Air leaks at
pressure switch
release valve.
Air leaks in air
tank or at air
tank welds.
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.
Defective pressure switch
release valve.
Defective air tank.
Leaking seal.
Air leaks
between head
and valve plate.
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
Overtighten,
A defective check valve
results in a constant 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.
Contact a Trained Service
Technician.
Air tank must be replaced.
Do not repair the leak.
Risk of
Bursting.
Do not drill into, weld or
otherwise modif_j air tank
or it will weaken. The tank
can rupture or explode,
Contact a Trained Service
Technician.
N004083 20- ENG