Craftsman 919.167784 User manual

Owners Manual
ICRRFTSMRN°I
Permanently Lubricated
2-Stage
Twin V
Portable
AIR COMPRESSOR
Model No.
919.167784
• Safety Guidelines
•Assembly
•Operation
•Maintenance
•Service and Adjustments
•Troubleshooting
•Repair Parts
CAUTION: Read the Safety Guidelines
and All Instructions Carefully Before
Operating.
Sold by Sears Canada, Inc. Toronto, Ont. M5B 2B8
N015838 Rev. 0 08/26/06

WARRANTY ................................................ 2
SPECIFICATIONS ........................................... 3
SAFETY GUIDELINES-DEFINITIONS ........................... 3
IMPORTANT SAFETY INSTRUCTIONS ........................ 3-9
GLOSSARY ................................................ 9
DUTY CYCLE .............................................. 9
ACCESSORIES ............................................ 10
ASSEMBLY ............................................... 10
INSTALLATION ......................................... 10-11
OPERATION ........................................... 12-14
MAINTENANCE ......................................... 14-15
SERVICE AND ADJUSTMENTS ............................ 16-17
STORAGE ................................................ 18
TROUBLESHOOTING GUIDE ............................. 19-21
REPAIR PARTS ......................................... 22-25
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
N015838 2- ENG

Model No.
Bore
Stroke High Pressure
Low Pressure
Voltage/Hz-Single Phase
Minimum Branch Circuit Requirement
Fuse Type
Air Tank Capacity (Gallon)
Approximate Cut-in Pressure
Approximate Cut-out Pressure
SCFM @40 psig
SCFM @ 90 psig
919.167784
2.375"
0.54"
1.45"
120
15 amps
Time Delay
25
145 PSIG
175 PSlG
*5.8
"5.1
*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.
m'v._lDT.,!_[€]=l;tl Indicates an
imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
IV!,,=,L,1;t _II#[_ Indicates a potentially
hazardous situation
which, if not avoided, could result in
death or serious injury.
I'v._[_.,1ll/[o]_ll 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 in property 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.
Do not operate this unit until you read this
instruction manual for safety, operation and
maintenance instructions.
SAVE THESE INSTRUCTIONS
3- ENG N015838

RISK OF EXPLOSION OR FIRE
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.
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'
(6.1 m) away from spray area. An
additional length of air hose may be
required.
• Store flammable materials in
a secure location away from
compressor.
• Never place objects against or on
top of compressor.
•Operate compressor in an open area
at least 12" (30.5 cm) away from
any wall or obstruction that would
restrict the flow of fresh air to the
ventilation openings.
•Operate compressor in a clean, dry
well ventilated area. Do not operate
unit in any confined area. Store
indoors.
•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
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.
HOW TO PREVENT IT
Never use air obtained directly
from the compressor to supply
air for human consumption. The
compressor is not equipped with
suitable filters and in-line safety
equipment for human consumption.
N015838 4- ENG

• Exposure to chemicals in dust
created by power sanding, sawing,
grinding, drilling, and other
construction activities may be
harmful.
• Sprayed materials such as paint,
paint solvents, paint remover,
insecticides, weed killers, may
contain harmful vapors and poisons.
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:
NIOSH/OSHA respiratory protection
or properly fitting face mask
designed for use with your specific
_RISK OF BURSTING
Air Tank: The air tank on your compressor is designed and may be UM coded
[for units with air tanks greater than 6" (152.4 mm) 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.
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.
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 N015838

Tires:
•Over inflation of tires could result
in serious injury and property
damage.
•Use a tire pressure gauge to check
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 pressure.
Add air in small increments and
frequently use the tire gauge to
over inflation.
RISK OF ELECTRICAL SHOCK
WHAT CAN HAPPEN
• Your compressor is powered by
electricity. Like any other electrically
powered device, if it is not used
properly it may cause electric shock.
Repairs attempted by unqualified
personnel can result in serious injury
or death by electrocution.
Electrical Grounding: Failure to
provide adequate grounding to this
product could result in serious injury
or death from electrocution. Refer to
Grounding Instructions paragraph
in the Installation section.
HOW TO PREVENT IT
• Never operate the compressor
outdoors when it is raining or in wet
conditions.
•Never operate compressor with
protective covers removed or
damaged.
•Any electrical wiring or repairs
required on this product should be
performed by authorized service
center personnel in accordance with
national and local electrical codes.
• Make certain that the electrical
circuit to which the compressor is
connected provides proper electrical
grounding, correct voltage and
adequate fuse protection.
N015838 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
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
"eS.
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.
__ _ RISK FROM
WHAT CAN HAPPEN
Moving parts such as the pulley,
flywheel, and belt can cause serious
injury if they come into contact with
you or your clothing.
Attempting to operate compressor
with damaged or missing parts or
attempting to repair compressor
with protective shrouds removed
can expose you to moving parts and
can result in serious iniury.
MOVING PARTS
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 beperformed by authorized
service center personnel.
7- ENG N015838

WHAT CAN HAPPEN
•Unsafe operation of your
compressor could lead to serious
injury or death to you or others.
__ _ RISK OF UNSAFE 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
[__ RISK OF FALLING
WHAT CAN 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 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.
__ RISK OF INJURY FROM LIFTING
WHAT CAN HAPPEN /HOW TO PREVENT IT
/
•Serious injury can result from / •The compressor is too heavy to
attempting to lift too heavy an be lifted by one person. Obtain
object, assistance from others before lifting.
N015838 8- ENG

__ RISK FROM NOISE
WHAT CAN HAPPEN t
• Under some conditions and duration [•
of use, noise from this product may
contribute to hearin 9 loss.
HOW TO PREVENT IT
Always wear certified safety
equipment: ANSI S12.6 ($3.19)
hearin 9 protection.
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 Underwriters
Laboratories Standards for Safety.
Cut-In Pressure: While the motor is
off, air tank pressure drops as you
continue to use your accessory. When
the tank pressure drops to a certain
low level the motor will restart auto-
matically. The low pressure at which
the motor automatically restarts is
called "cut-in" pressure.
Cut-Out Pressure: When an air
compressor is turned on and begins
to run, air pressure in the air tank
begins to build. It builds to a certain
high pressure before the motor auto-
matically shuts off - protecting your
air tank from pressure higher than its
capacity. The high pressure at which
the motor shuts off is called "cut-out"
pressure.
Branch Circuit: Circuit carrying elec-
tricity from electrical panel to outlet.
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 N015838

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
Unpacking
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.
1. Remove unit from carton and dis-
card 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 in the vertical posi-
tion resting on the rubber bum-
pers 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
grounding wire with an appropriate
grounding plug (see following illustra-
tions).
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.
2. Make sure the outlet being used
has the same configuration as the
grounded plug. DO NOT USE AN
ADAPTER. See illustration.
N015838 10- ENG

Plug
@Grounded
Outlets
Grounding Pin
.
.
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
compressor is properly grounded,
have the installation checked by a
qualified electrician.
W.v_l=7¢__[€1=1".1_ 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 elec-
trician.
Extension Cords
Using extension cords is not recom-
mended. The use of extension cords
will cause voltage to drop resulting in
power loss to the motor and overheat-
ing.
Instead of using an extension cord,
increase the working reach of the
air hose by attaching another length
of hose to its end. Attach additional
lengths of hose as needed.
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
• 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.)
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 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.
11- ENG N015838

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.
Auto(I)/Off(O) Switch: Place this
switch in the "Auto (I)" position to pro-
vide automatic power to the pressure
switch and "Qff (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
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
pressure gauge indicates the reserve
air pressure in the tank.
N015838
Regulator: Controls the air pressure
shown on the outlet pressure gauge.
Pull the knob out and turn clockwise
to increase pressure and counter-
clockwise to decrease pressure. When
the desired pressure is reached push
knob in to lock in place.
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 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.
12- ENG

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.
Pressure Release Valve: The pres-
sure release valve located on the side
of the pressure switch, is designed to
automatically release compressed air
from the compressor head and the
outlet tube when the air compressor
reaches "cut-out" pressure or is shut
off. The pressure release valve allows
the motor to restart freely. When the
motor stops running, air will be heard
escaping from this valve for a few
seconds. No air should be heard
leaking when the motor is running, or
continuous leaking after unit reaches
"cut-out" pressure.
How to Use Your Unit
How to Stop
1. Set the Auto/Off lever to "Off".
Before Starting
Do not operate this
unit until you read this
instruction manual for safety, operation
and maintenance instructions.
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 Auto/Off lever is in
the "Off" position.
NOTE: Pull 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.
4. Move the Auto/Off lever 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 lever to "Off".
2. Pull the regulator knob out and
turn counterclockwise to set the
outlet pressure to zero.
3. Visually inspect air hose, replace if
needed.
4. 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 socket.
13- ENG N015838

Risk of Flying
Objects. Pull
the regulator knob out and turn
counter-clockwise to set the outlet
pressure to zero when removing
hose or accessories to prevent
hose backlash.
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.
Risk of Bursting.
I'oo 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 Auto/Off lever to "Auto"
and allow tank pressure to build.
Motor will stop when tank pres-
sure reaches "cut-out" pressure.
2. Pull the regulator knob out and
turn clockwise to increase pres-
sure. When the desired pressure
is reached push knob in to lock in
place. Risk of unsafe
operation. 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.
Customer Responsibilities
Before Daily Every Yearly
each or after 100
use each hours
use
Check Safety Valve
Drain Tank
Air Filter
Air compressor pump X
intake and exhaust valves
1- more frequent in dusty or humid conditions
N015838 14-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.
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 work-
ing environment operating on a daily
basis. If necessary, the schedule
should be modified to suit the condi-
tions under which your air 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 fre-
quency 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.
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. Air tanks
contain high pressure air. Keep face
and other body parts away from
outlet of drain. Use eye protection
[ANSI Z87.1 (CAN/CSA Z94.3)] when
draining as debris can be kicked up
into face.
Risk from noise.
Use ear protection
(ANSI $12.6 ($3.19) as air flow noise
is loud when draining.
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/Off lever 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.
15- ENG N015838

Air Filter Inspection and
Replacement Hot surfaces.
Risk of burn.
Compres-sor heads are exposed
when filter cover is removed.
Allow compressor to cool prior to
servicing.
Keep the air filter
clean at all times.
Do not operate the air compressor
with the air filter removed.
A dirty air filter will not allow the com-
pressor to operate at full capacity.
Keep the air filter clean at all times.
1. Remove the air filter cover.
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.
Air Filter
Cover
ALL MAINTENANCE AND REPAIR
OPERATIONS NOT LISTED MUST
BE PERFORMED BY A 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 Auto/Off lever to "Off" and
unplug unit.
3. Using a phillips screwdriver,
remove the air filter cover.
4. Remove the rear shrouds using
T-20 torx wrench.
N015838 16- ENG
Remove Remove
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 2. Set the Auto/Off lever to "Off" and
unplug unit.
3. Remove the outlet pressure gauge
and quick connect (if equipped)
from the regulator.
7. Unscrew the check valve (turn
counterclockwise) using a 7/8"
open end wrench. NOTE the ori-
entation for reassembly.
8. 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 posi-
tion; if not the check valve needs to be
cleaned or replaced.
Screwdriver
position
nothing is
visible.
In 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 tight-
en nut.
13. Replace the shroud and air filter.
14. Perform the break-in procedure.
See Break-in Procedure in the
Operation section.
To Replace Regulator
1. Release all air pressure from air
tank. See To Drain Tank in the
Maintenance section.
4. Remove the regulator.
5. Apply pipe sealant tape to the
nipple.
6. Assemble the regulator and orient
as shown.
Regulator
NOTE: Arrow indicates flow of air.
Make sure it is pointing in the direction
of air flow.
.
.
Reapply pipe sealant to outlet
pressure gauge and quick con-
nect.
Reassemble outlet pressure
gauge and quick connect. Orient
outlet pressure gauge to read cor-
rectly. Tighten quick connect with
wrench.
17- ENG N015838

Before you store the air compressor,
make sure you do the following:
1. Review the Maintenance section
on the preceding pages and per-
form scheduled maintenance as
necessary.
2. Set the Auto/Off lever to "Off" and
unplug unit.
3. Risk of Flying
Objects. Pull
the regulator knob out and turn
counterclockwise to set the out-
let pressure to zero when
removing hose or accessories to
prevent hose backlash.
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 open-
ing drain valve on bottom of tank.
Risk of Bursting.
Water will
condense in the air tank. If not
drained, water will corrode and
weaken the air tank causing a risk
of air tank rupture.
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, and reinstalled.
8. Protect the electrical cord and air
hose from damage (such as being
stepped on or run over). Wind
them loosely around the compres-
sor handle.
9. Store the air compressor in a clean
and dry location.
N015838 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
Excessive
tank pressure
-safety valve
oops off.
Air leaks at
fittings.
Air leaks at or
inside check
valve.
Air leaks at
pressure
switch release
valve.
Air leaks in air
tank or at air
tank welds.
Air leaks
between head
and valve
plate.
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.
CORRECTION
Move Auto/Off lever to the
"Off" position, if the outfit
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
to 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 modify air tank or
it will weaken. The tank can
rupture or explode.
Contact a Trained Service
Technician.
19- ENG NO15838

PROBLEM
Pressure
reading on
the regulated
pressure
gauge drops
when an
accessory is
used.
CAUSE
It is normal for "some"
pressure drop to occur.
Knocking
Noise. Possible defect in safety
valve.
CORRECTION
If there is an excessive
amount of pressure drop when
the accessory is used, adjust
the regulator following the
_nstructions in the Description
of Operation paragraph in the
Operation section.
NOTE: Adjust the regulated
pressure under flow
conditions (while accessory is
being used).
Operate safety valve manually
by pulling on ring. If valve still
leaks, it should be replaced.
Compressor is not large
enough for air requirement.
Defective check valve. Remove and clean, or replace.
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.
Damaged regulator.Regulator
knob has
continuous air
leak.
Regulator will
not shut off air
outlet.
Damaged regulator.
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.
Remove and clean, or replace.
Tighten fittings.
Clean or replace air intake
filter. Do not operate the
air compressor with the
filter removed. Refer to the
Air Filter paragraph in the
Maintenance section.
Replace.
Replace.
N015838 20- ENG