Craftsman 919.167621 User manual

Owner's Manual
ICRFIFTSMI:IN°I
PermanentJy Lubricated
Single Stage
PortabJe
AiR COMPRESSOR
Model No.
919.167621
=Safety Guidelines
=Assembly
=Operation
=Maintenance
=Troubleshootincj
=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
N004395 Rev.0 02/11/08

WARRANTY ................................................ 2
SPECiFiCATiON CHART ...................................... 3
SAFETY GUiDELiNES ...................................... 3-8
GLOSSARY ................................................ 9
ACCESSORIES ............................................ 10
DUTY CYCLE .............................................. 10
ASSEMBLY ............................................... 10
INSTALLATION ......................................... 10-12
OPERATION ............................................ 12-14
MAINTENANCE ......................................... 15-16
SERVICE AND ADJUSTMENTS ............................ 17-18
STORAGE ................................................ 18
TROUBLESHOOTING GUIDE .............................. 19-21
REPAIR PARTS ......................................... 22-25
ESPAI_OL .............................................. 26-45
NOTES/NOTAS ............................................ 46
REPAIR PROTECTION AGREEMENTS ......................... 47
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
N004395 2-ENG

Model No. 919.167621
Running HP "1.6
Bore 2.875"
Stroke 1.45"
Voltage-Single Phase 120V/60HZ
Minimum Branch Circuit Requirement 15 amps
Fuse Type Time Delay
Air Tank Capacity (gallons) 33
Approx. Cutqn 120 PSi
Approx. Cut-out 150 PSI
SCFM @40 psig *6.4
SCFM @90 psig *5.0
* Tested per ISO 1217
Refer to Glossary for abbreviations,
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 symbols.
Indicates an
imminently
hazardous situation which, if not
avoided, will result in death or
serious inNuJ3t.
_ ndicates a
potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
_ ndicates a
potentially
hazardous situation which, if not
avoided, _ result in minor or
moderate in"ULU_r_.
Used without the
safety alert symbol
indicates apotentially hazardous
situation which, if not avoided, may
result in property damac_.
This product contains chemicals known to the State of
California to cause cancer, and birth defects or other repro-
ductive harm. Wash hands after handling.
Some dust contains chemicals known to the State of
California to cause cancer, birth defects or other reproduc-
tive harm such as asbestos and lead in lead based paint.
Do not operate this unit until you read and _
'"__ understand this instruction manual for safety,
_operation and maintenance instructions.
SAVE THESE INSTRUCTIONS
3-ENG N004395

RISK OF EXPLOSION OR FiRE
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.
• •
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.
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.
Store flammable materials in
a secure location away from
cornpressor.
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.
Always turn off and unplug unit
when not in use.
__ RiSK TO BREATHING (ASPHYXiATiON}
WHAT CAN 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 air tank. Breathing these
contaminants can cause serious
injury or death.
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.
N004395 4-ENG

• • 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.
R sKoFBURSTING
Sprayed materials such as paint,
paint solvents, paint remover,
insecticides, weed killers, may
contain harmful vapors and
poisons.
Air Tank: The air tank on your Air Compressor is designed and may be UM coded
(for units with air tanks greater than 6" (152 mm) 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 HOW TO PREVENT IT
Failure to properly drain condensed • Drain air tank daily or after each
water from air tank, causing rust use. If air tank develops a leak,
and thinning of the steel air tank. replace it immediately with a
new air tank or replace the entire
cornpressor.
Modifications or attempted repairs
to the air tank. 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.
Unauthorized modifications to • The air tank is designed to
the safety valve or any other withstand specific operating
components which control air tank pressures. Never make adjustments
pressure, 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.
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 N004395

Tires:
• Over inflation of tires could result in • Use a tire pressure gauge to check
serious injury and property damage, the tires pressure before each use
and while inflating tires; see the tire
sidewall for the correct tire pressure.
NOTE: Air tanks, compressors and similar
equipment used to inflate tires can fill
small tires similar to these very rapidly.
Adjust pressure regulator on air supply
to no more than the rating of the tire
)ressure. Add air in small increments and
frequently use the tire gauge to prevent
over inflation.
RiSKoFELECTRICALSHOCK
WHAT CAN HAPPEN HOW TO PREVENT iT
• •
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 'qnstallation"
section.
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 personnell 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.
N004395 6-ENG

_I__ RiSK FROM FLYING OBJECTS
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.
HOW TO PREVENT IT
Always wear certified safety
equipment: ANSI Z87.1 eye
protection (CAN/CSA Z94.3)
with side shields when using the
com pressor.
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.
RiskOFHOTSURFACES
WHAT CAN HAPPEN 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.
ov,°o..o.s
Touching exposed metal such as
the compressor head, engine head,
engine exhaust or outlet tubes, can
result in serious burns.
WHAT CAN HAPPEN HOW TO PREVENT IT
• •
Moving parts such as the pulley,
flywheel, and belt can cause
serious injury if they come into
contact with you or your clothing.
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.
7-ENG N004395

• 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.
RiskorUNSAFEOPERATION
Any repairs required on this product
should be performed by authorized
service center personnel.
WHAT CAN HAPPEN 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 afire
extinguisher.
Do not operate machine with
missing, broken, or unauthorized
parts.
Unsafe operation of your air
compressor could lead to serious
injury or death to you or others.
RiskorrALUNG
WHAT CAN HAPPEN HOW TO PREVENT IT
• • Always operate compressor in a
stable secure position to prevent
accidental movement of the unit.
Never operate compressor on a
roof or other elevated position.
Use additional air hose to reach
high locations.
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.
N004395 8-ENG

__ RiSK OF iNJURY FROM LiFTiNG
WHAT CAN HAPPEN
= Serious injury can result from
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 HOW TO PREVENT IT
= Under some conditions and = Always wear certified safety
duration of use, noise from this equipment: ANSI S12.6 (S3.19)
product may contribute to hearing hearing protection.
loss. SAVE THESE INSTRUCTIONS
FOR FUTURE USE
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 evaluated by OSHA certified
independent safety laboratories and
meet the applicable 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 com-
pressor 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 automati-
cally 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.
9-ENG N004395

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.
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.
Unpacking
1. Remove unit from carton and
discard all packaging.
HOW TO SET UP YOUR UNIT
Location of the Air Compressor
• Locate the air compressor in a
clean, dry and well ventilated
area.
• The air compressor should be
located at least 12" (30.5 cm)
away from the wall or other
obstructions that will interfere
with the flow of air.
• Place the air compressor on a flat
level surface resting on the rub-
ber bumpers and wheels
• The air compressor pump and
shroud are designed to allow for
proper cooling. The ventilation
openings on the compressor are
necessary to maintain proper
operating temperature. Do not
place rags or other containers on
or near these openings.
GROUNDING iNSTRUCTiONS
_Risk of Electrical
-- Shock. in the event
of a short circuit, grounding reduces
the risk of shock by providing an
escape wire for the electric current.
This air compressor must be
properly grounded.
The portable air compressor is
equipped with a cord having a ground-
ing wire with an appropriate grounding
plug (see following illustrations).
1. The cord set and plug with this
unit contains a grounding pin.
This plug MUST be used with a
grounded outlet.
iMPORTANT: The outlet being used
must be installed and grounded in
accordance with all local codes and
ordinances.
N004395 10-ENG

2. Make sure the outlet being used
has the same configuration as the
grounded plug. DO NOT USE AN
ADAPTER. See illustration.
attaching another length of hose to
its end. Attach additional lengths of
hose as needed. Always use an air
hose rated 300 PSI or greater.
g [-'_LGrounded
Grounding Pin
3.
4.
Inspect the plug and cord before
each use. Do not use if there are
signs of damage.
If these grounding instructions are
not completely understood, or if in
doubt as to whether the compres-
sor is properly grounded, have the
installation checked by a qualified
electrician.
_Risk of Electrical
Shock. IMPROPER
GROUNDING CAN RESULT IN
ELECTRICAL SHOCK.
Do not modify the plug provided. If
it does not fit the available outlet, a
correct outlet should be installed by
a qualified electrician.
Repairs to the cord set or plug
MUST be made by a qualified
electrician.
EXTENSION CORDS
If an extension cord must be used, be
sure it is:
• a 3-wire extension cord that has
a 3-blade grounding plug, and a
3-slot receptacle that will accept
the plug on the product
• in good condition
• no longer than 50 feet (15.2 m)
• 12 gauge (AWG) or larger. (Wire
size increases as gauge number
decreases. 10 AWG and 8 AWG
may also be used. DO NOT USE
14 OR 16 AWG.)
The use of an
_" " "-- undersized extension
cord will cause voltage to drop
resulting in power loss to the motor
and overheating. Instead of using
an extension cord, increase the
working reach of the air hose by 11- ENG
VOLTAGE AND CiRCUiT
PROTECTION
Refer to the specification chart for the
voltage and minimum branch circuit
requirements.
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 compres-
sor 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.
TRANSPORTING
When transporting the compressor in a
vehicle, trailer, etc., make sure the tank
is drained and the unit is secured with
straps to prevent tipping. Use care
when driving to prevent tipping the unit
over in the vehicle. Damage can occur
to the compressor or surrounding
items if the compressor is tipped.
Lifting
Always use two
people when lift-
ing and lift from
the recommended
lift points. DO
NOT lift by wheels
or shroud.
N004395

Moving
The wheels and
handle do not provide
adequate clearance, stability, or
support for pulling the unit up and
down stairs or steps. The unit must be
lifted or pushed up a ramp.
1. Grasp handle of compressor and
tilt compressor back to rest on
wheels.
Risk of Unsafe
Operation. Ensure
proper footing and use caution
when rolling compressor so that
unit does not tip or cause loss of
balance.
2. When location is reached slowly
lower compressor to ground.
Always store compressor in a
vertical position resting on the
rubber bumpers and wheels.
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.
,Pressure Tank Pressure Gauge
Switch
':Regulator
Description of Operation
Become familiar with these controls
before operating the unit.
Auto (I)/Off (O) Switch: Turn this
switch "Auto (I)" to provide automatic
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" pressure. It stops
the motor when the air tank pressure
reaches the factory set "cut-out" pres-
sure.
Safety Valve: If the pressure switch
does not shut off the air compressor
at its "cut-out" pressure setting, the
N004395
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).
Outlet Pressure Gauge: The outlet
pressure gauge indicates the air pres-
sure available at the outlet side of the
regulator. This pressure is controlled by
the regulator and is always less than or
equal to the tank pressure.
Tank Pressure Gauge: The tank pres-
sure gauge indicates the reserve air
pressure in the tank.
Regulator: Controls the air pressure
shown on the outlet pressure gauge.
Pull the knob out and turn clockwise
to increase pressure and counterclock-
wise to decrease pressure. When the
desired pressure is reached push knob
in to lock in place.
12- ENG

Universal Quick=Connect Body: The
universal quick-connect body accepts
the three most popular styles of quick-
connect plugs: Industrial, automotive
(Tru-flate), and ARO. One hand push-
to-connect operation makes connec-
tions simple and easy.
Drain Valve:
The drain valve is
located at the
base of the air
tank and is used
to drain conden-
sation 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.
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 pres-
sure switch, is
designed to
automatically release compressed air
from the compressor head and the out-
let tube when the air compressor reach-
es "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
is running or after the unit reaches "cut-
out" pressure.
Air Intake Filter:
This filter is
designed to clean
air coming into the
pump. This filter
must always be
clean and ventila-
tion openings free
from obstructions. See "Maintenance".
Motor Overload Protector: The motor
has a 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. Set the Auto/Off switch to "Off"
and unplug unit.
2. Allow the motor to cool.
3. Plug the power cord into the
correct branch circuit receptacle.
4. Set the Auto/Off lever to "Auto"
position.
HOW TO USE YOUR UNIT
How to Stop
1. Set the Auto/Off switch to "Off".
NOTE: When the unit has been turned
off, it is normal to hear a short hiss of
air being released.
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 Auto/Off switch is
in the "Off" position.
13-ENG N004395

NOTE: Push coupler back until it
clicks to prevent air from escaping
through the quick connect.
2. Plug the power cord into the
correct branch circuit receptacle.
(Refer to Voltage and Circuit
Protection paragraph in the
Installation section of this
manual.)
3. Open the drain valve (counter-
clockwise) fully to permit air to
escape and prevent air pressure
build up in the air tank during the
break-in period.
_Risk from Flying
__ Objects. Always
wear certified safety equipment:
ANSi Z87.1 eye protection (CAN/
CSA Z94.3) with side shields as
debris can be kicked up into face.
4. Move the Auto/Off switch to
"Auto" position. The compressor
will start.
5. Run the compressor for 15
minutes. Make sure the drain
valve is open and there is
minimal air pressure build-up in
tank.
6. After 15 minutes, close the drain
valve by turning clockwise. The
air receiver will fill to "cut-out"
pressure and the motor will
stop.
The compressor is now ready for use.
Before Each Start=Up
1. Place Auto/Off switch to "Off".
2. Pull regulator knob out, turn
counter-clockwise until it stops.
Push knob in to lock in place.
3. Attach hose and accessories.
NOTE: The hose or accessory will
require a quick connect plug if the
air outlet is equipped with a quick
connect.
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.
_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.
Bow to Start
1. Turn the Auto/Off switch to
"On/Auto" and allow tank pres-
sure to build. Motor will stop
when tank pressure reaches "cut-
out" pressure.
2. Pull the regulator knob out and
turn clockwise to increase
pressure. When the desired
pressure is reached push knob in
to lock in place. The compressor
is ready for use.
Risk of fire or
explosion. Always
operate the air compressor in well=
ventilated areas free of gasoline
or other combustible vapors, if
the compressor is being used to
operate a sprayer DO NOT place
near the spray area.
_lf 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.
N004395 14-ENG

CUSTOMER RESPONSiBiLiTiES
Procedure Daily Daily Weekly
or after
each use
Check safety valve X
inspect air filter X1
Drain air tank X
Check for unusual noise/vibration X
Check for air leaks* X
Clean compressor exterior X
*To check for air leaks apply a solution of soapy water around joints.
While compressor is pumping to pressure and after pressure cuts
out, look for air bubbles to form.
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.
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.
Beforestarting compressor, pullthe ring on
the safetyvalveto makesurethat the safety
valve operates freely.Ifthe valve is stuck
or does not operate smoothly, it must be
replaced with the sametype 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 S12.6
($3.19} hearing protection] as air
flow noise is loud when draining.
15-ENG N004395

NOTE: All compressed air systems
generate condensate that accumulates
in any drain point (e.g., tanks, filter, after-
coolers, dryers). This condensate con-
tains lubricating oil and/or substances
which may be regulated and must be
disposed of in accordance with local,
state, and federal laws and regulations.
1. Set the Auto/Oft switch to "Off"
and unplug unit.
2. Pull the regulator knob out and
turn counterclockwise 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 open-
ing 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.
Risk of property
damage. Drain
water from air tank may contain oil
and rust which can cause stains.
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, the rein-
stalled.
AiR FILTER
_Hot surfaces. Risk
__ of burn. Outlet
tube, pump head, and surrounding
parts are very hot, do not touch.
Allow compressor to cool prior to
servicing.
1. Place Auto/Oft switch to "Off".
2. Allow unit to cool.
3. Remove filter cover from base.
4. Remove element from filter base.
5. Place new element back in filter
base. Purchase replacement parts
from your local dealer or autho-
rized service center. Always use
identical replacement parts.
6. Snap filter cover to filter base.
_Risk of property
__ damage. Do not
operate without air inlet filter
N004395 16-ENG

Risk of unsafe
operation. Unit
cycles automatically when power is
on. When doing Maintenance, you
may be exposed to voltage sources,
compressed air or moving parts.
Personal injuries can occur.
Before servicing:
• Unplug or disconnect
electrical supply to the air
compressor.
®Bleed tank of pressure.
• Allow the air compressor to
cool.
ALL MAINTENANCE AND REPAIR
OPERATIONS NOT LISTED MUST
BE PERFORMED BY TRAINED
SERVICE TECHNiCiAN.
TO REPLACE CHECK VALVE
1. Release all air pressure from air
tank. See "To Drain Tank" in the
Maintenance section.
2. Unplug outfit.
3. Remove the shroud on the outlet
tube side. NOTE: Remove screw
with T-20 Torx screwdriver and
loosen all the tabs on the shroud
with a flat screwdriver before
removing.
5.
6.
7.
Using an
adjust-
able
wrench
loosen
pressure
relief
tube nut
at air
tank.
Carefully Pressure Relief Tube
move pressure relief tube away
from check valve
Unscrew the check valve (turn
counterclockwise) using a 7/8"
open end wrench. Note the orien-
tation for reassembly.
Using a screwdriver, carefully push
the valve disc up and down.
position
nothing is
visible.
In closed position
disc is visible.
4. Using an adjustable wrench, loos-
en outlet tube nut at air tank and
pump head. Carefully move outlet
tube away from check valve.
NOTE: The valve disc should move
freely up and down on a spring which
holds the valve disc in the closed posi-
tion; if not the check valve needs to be
replaced.
8. Install the new check valve (turn
clockwise).
9. Replace the pressure release tube.
Tighten nut.
10. Replace the outlet tube and tight-
en nuts.
11. Replace the shroud.
12. Perform the Break-in Procedure.
See "Break-in Procedure" in the
Operation section.
17-ENG N004395

7. Assemble quick connect to new
regulator and tighten.
TO REPLACE REGULATOR
1. Release all air pressure from air
tank. See "To Drain Tank" in the
Maintenance section.
2. Unplug compressor.
3. Remove shrouds.
4. Remove the outlet pressure gauge
and quick connect from the
regulator.
Outlet
Pressure
5. Remove the regulator.
6. Reapply pipe sealant to outlet
pressure gauge and quick
connect.
Regulato
Connect
8. Apply pipe sealant tape to the
nipple.
9. Assemble the regulator. NOTE:
Arrow indicates flow of air. Make
sure it is pointing in the direction
of air flow.
10. Use the hex on quick connect
to tightening regulator. Orient as
shown.
11. Assemble outlet pressure gauge.
Orient outlet pressure gauge to
read correctly.
12. Replace shrouds.
Before you store the air compressor,
make sure you do the following:
1. Review the "Maintenance" sec-
tion on the preceding pages and
perform scheduled maintenance
as necessary.
2. Set the Auto/Off lever to "Off".
3. Turn the regulator counterclock-
wise and set the outlet pressure
to zero.
4. Remove the air tool or accessory.
5. Pull ring on safety valve allowing
air to bleed from the tank until
tank pressure is approximately 20
PSI. Release safety valve ring.
6. Drain water from air tank by
opening 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. To protect the electrical cord
from damage wind electrical cord
loosely around the compressor
handle.
Store the air compressor in a clean
and dry location.
N004395 18- ENG

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 CAUSE CORRECTION
Excessive Pressure switch does not Move Auto/Off lever to the
tank pressure shut off motor when "Off" position, if the outfit
- safety valve compressor reaches does not shut off contact a
pops off. "cut-out" pressure. Trained Service Technician.
Pressure switch "cut-out" Contact a Trained Service
too high. Technician.
Air leaks at fit- Tube fittings are not tight Tighten fittings where air can
tings, enough, be heard escaping. Check fit-
tings with soapy water solu=
tion. Do Not Overtighten.
Check valve seat damaged.
Air leaks at or
inside check
valve.
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 to the "To Replace
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 leaks Leaking seal.
between head
and valve plate.
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.
Contact a Trained Service
Technician.
19-ENG N004395

PROBLEM CORRECTION
Pressure read-
ing on the regu-
lated pressure
gauge drops
when an acces-
sory is used.
CAUSE
It is normal for "some"
3ressure drop to occur. If there is an excessive amount of pressure drop when
the accessory is used, adjust
the regulator following the
instructions in the "Description
of Operation" paragraph in the
Operation section.
NOTE: Adjust the regulated
pressure under flow
conditions (while accessory is
being used).
Compressor is not large
enough for air requirement.
Knocking Noise. Possible defect in safety Operate safety valve manually
valve, by pulling on ring. If valve still
leaks, it should be replaced.
Defective check valve. Replace check valve.
Compressor is Prolonged excessive use of Decrease amount of air usage.
not supplying air.
enough air
to operate
accessories.
Hole in hose.
Check valve restricted.
Air leaks.
Restricted air intake filter.
Check the accessory air
requirement. If it is higher
than the SCFM or pressure
supplied by your air
compressor, you need a
larger compressor.
Check and replace if required.
Replace check valve.
Tighten fittings.
Clean or replace air intake
filter. Do not operate the
air compressor with the fil-
ter removed. Refer to the
"Air Filter" paragraph in the
Maintenance section.
Regulator knob Damaged regulator. Replace.
has continuous
air leak.
Regulator will Damaged regulator. Replace.
not shut off air
outlet.
N004395 20-ENG