Craftsman 919.176502 User manual

ICRAFTSMAN1
Oil Lubricated
Two Stage
Stationary
AIR COMPRESSOR
Model No.
919.176502
•Safety Guidelines
•Assembly
• Operation
• Maintenance
• Service and Adjustments
•Troubleshooting
•Repair Parts
CAUTION: Read the Safety Guidelines and
All Instructions Carefully Before Operating.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Visit our Craftsman website: www.sears.com/craftsman
D26056 Rev. 1 9/20/04

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WARRANTY ................................................ 2
SPECIFICATION CHART ..................................... 3
SAFETY GUIDELINES ...................................... 3-8
GLOSSARY ................................................ 9
ACCESSORIES ............................................. 9
DUTY CYCLE .............................................. 9
ASSEMBLY ............................................... 10
INSTALLATION .......................................... 11-12
OPERATION ............................................ 13-15
MAINTENANCE ......................................... 16-17
SERVICE AND ADJUSTMENTS ............................ 18-19
STORAGE ................................................ 20
TROUBLESHOOTING GUIDE .............................. 21-23
REPAIR PARTS ......................................... 24-27
ESPAI_IOL .............................................. 28-49
NOTES/NOTAS ......................................... 50-51
HOW TO ORDER REPAIR PARTS ...................... back cover
FULL ONE YEAR WARRANTY AIR COMPRESSOR
If this air compressor fails due to a defect in material or workmanship within
one year from the date of purchase, RETURN IT TO THE NEAREST SEARS
REPAIR CENTER THROUGHOUT THE UNITED STATES AND SEARS WILL
REPAIR IT, FREE OF CHARGE, If purchased from Orchard Supply Hardware,
return to the nearest Orchard Store and Orchard will repair it, free of charge,
If this air compressor is used for commercial or rental purposes, the warranty
will apply for 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, II 60179
D26056 2-ENG

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Model No. 919-176502
Max. Developed HP 5
Bore 3.54"
Stroke 1.97"
Voltage-Single Phase 240
Motor Phase 1
Minimum Branch Circuit Requirement 20 amps
Fuse Type Time Delay
Air Tank Capacity 60
Approx. Cut-In 140
Approx. Cut-out 175
SCFM @ 100 psig 12.0
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This manual contains information that is important for you to know and understand. This information
relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you
recognize this information, we use the symbols below. Please read the manual and pay attention to
these sections.
_mminently hazardous
situation which, if not avoided, will
result in death or serious injury.
_lndicates a potentially
hazardous situation
which, if not avoided, could result in
death or serious injury.
_lndicates a potentially
hazardous situation
which, if not avoided, _ result in
minor or moderate injury.
_Used without the
safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may
result in property damage.
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SAVE THESE INSTRUCTIONS _
_w
IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN
SERIOUS INJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL
WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT.
Some dust created by power sanding, sawing, grinding, drilling, and other
construction activities contains chemicals known (to the State of California) to
cause cancer, birth defects or other reproductive harm. Some example of these chemicals are:
• lead from lead-based paints
• crystalline silica from bricks and cement and other masonry products
• arsenic and chromium from chemically-treated lumber
Your risk from these exposures varies, depending on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well ventilated area, and work with approved safety
equipment, always wear MSHA/NIOSH approved, properly fitting face mask or respirator when using
such tools.
When using air tools, basic safety precautions should always be followed to reduce the risk of of
personal injury.
3-ENG D26056

Save these instructions
Improper operation or maintenance of this product could result in serious injury and
property damage. Read and understand all warnings and operation instructions before
using this equipment.
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WARNING: Risk of explosion or fire
What Could 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 feet away from
spray area. An additional length of hose
may be required.
Store flammable materials in asecure
location away from compressor.
Never place objects against or on top
of compressor. Operate compressor in
an open area at least 12 inches away
from any wall or obstruction that would
restrict the flow of fresh air to the
ventilation openings.
Operate compressor in a clean, dry well
ventilated area. Do not operate unit
indoors or in any confined area.
Always remain in attendance with the
)roduct when it is operating.
Always disconnect electrical power by
moving pressure switch lever to the off
)osition and drain tank daily or after
each use.
D26056 4-ENG

:V;YJ;I;1m_
WARNING: Risk of Bursting I_1
Air Tank: The following conditions could lead to a weakening of the tank, and result
in a violent tank explosion and could cause property damage or serious injury.
What Could Happen
Failure to properly drain
condensed water from tank,
causing rust and thinning of the
steel tank.
2. Modifications or attempted repairs
to the tank.
3. Unauthorized modifications to the
unloader valve, safety valve, or any
other components which control
tank pressure.
4. Excessive vibration can weaken
the air tank and cause rupture or
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 tank daily or after each use. If
tank develops a leak, replace it
immediately with a new tank or replace
the entire compressor.
Never drill into, weld, or make any
modifications to the tank or its
attachments.
The tank is designed to withstand specific
operating pressures. Never make
adjustments or parts substitutions to
alter the factory set operating
pressures.
For essential control of air pressure, you
must install a pressure regulator and
pressure gauge to the air outlet (if not
equipped) of your compressor. Follow the
equipment manufacturers
recommendation and never exceed the
maximum allowable pressure rating of
attachments. Never use compressor to
inflate small low pressure objects such
as children's toys, footballs,
basketballs, etc.
:V;YJ;I;tm_
WARNING: 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 ANSI Z87.1 approved safety
glasses with side shields when using the
compressor.
Never point any nozzle or sprayer
toward any part of the body or at other
people or animals.
Always turn the compressor oft and
bleed pressure from the air hose and tank
before attempting maintenance, attaching
tools or accessories.
5-ENG D26056

I: V.._:l I'lm]
WARNING: Risk of Electrical Shock
WHAT CAN HAPPEN
Your air compressor is powered by
electricity. Like any other electrically
powered device, If it is not used properly
it may cause electric shock.
Repairs attempted by unqualified
personnel can result in serious injury or
death by electrocution.
Electrical Grounding: Failure to provide
adequate grounding to this product
could result in serious injury or death
from electrocution.
See grounding instructions.
HOW TO PREVENT IT
Never operate the compressor outdoors
when it is raining or in wet conditions.
Never operate compressor with
protective covers removed or damaged.
Any electrical wiring or repairs required
on this product should be performed by
authorized service center personnel in
accordance with national and local
electrical codes.
Make certain that the electrical circuit
to which the compressor is connected
provides proper electrical grounding,
correct voltage and adequate fuse
protection.
I: V;Y_;I;tm]
WARNING: Risk to Breathing
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 tank. Breathing these
contaminants can cause serious injury
or death.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides,
weed killers, may contain harmful vapors
and poisons.
HOW TO PREVENT IT
Air obtained directly from the compressor
should never be used to supply air for
human consumption. In order to use air
produced by this compressor for
breathing, suitable filters and in-line
safety equipment must be properly
installed. In-line filters and safety
equipment used in conjunction with the
compressor must be capable of treating
air to all applicable local and federal
codes prior to human consumption.
Work in an area with good cross
ventilation. Read and follow the safety
instructions provided on the label or
safety data sheets for the materials you
are spraying. Use a NIOSH/MSHA
approved respirator designed for use
with your specific application.
D26056 6-ENG

I: F.._I.lI'lm]
WARNING: RISK OF BURNS
WHAT CAN HAPPEN
Touching exposed metal such as the
compressor head or outlet tubes, can
result in serious burns.
HOW TO PREVENT IT
Never touch any exposed metal parts
on compressor during or immediately
after operation. Compressor will remain
hot for several minutes after operation.
Do not reach around protective shrouds
or attempt maintenance until unit has
been allowed to cool.
I: F.._I.lI'lm]
WARNING: RISK FROM MOVING PARTS _ _
WHAT CAN HAPPEN HOW TO PREVENT IT
Moving parts such as the pulley, flywheel, Never operate the compressor with
and belt can cause serious injury if they guards or covers which are damaged or
come into contact with you or your removed.
clothing.
Attempting to operate compressor with Any repairs required on this product
damaged or missing parts or attempting should be performed by authorized
to repair compressor with protective service center personnel.
shrouds removed can expose you to
moving par_s and can result in serious
injury.
I: FI._I.lI'lm]
WARNING: RISK OF FALLING
WHAT CAN HAPPEN HOW TO PREVENT IT
A portable compressor can fall from atable, Always operate compressor in a stable secure
workbench or roof causing damage to the position to prevent accidental movement of the
compressor and could result in serious unit.Never operate compressor on a roof or
injuryor death to the operator, other elevated position. Use additionalair
hose to reach high locations.
I: F.._I.lI'lm]
WARNING: RISK OF SERIOUS INJURY OR PROPERTY I_]
DAMAGE WHEN TRANSPORTING COMPRESSOR
(Fire, Inhalation, Damage to Vehicle Surfaces)
WHAT CAN HAPPEN HOW TO PREVENT IT
Oil can leak or spill and could result in Always place compressor on a
fire or breathing hazard; serious injury or protective mat when transporting to
death can result. Oil leaks will damage protect against damage to vehicle from
carpet, paint or other surfaces in vehicles leaks. Remove compressor from vehicle
or trailers, immediately upon arrival at your
destination.
7_ENG D26056

I:V;YJ;I;1m]
WARNING: RISK OF UNSAFE OPERATION
WHAT CAN HAPPEN
Unsafe operation of your air compressor
could lead to serious injury or death to
you or others,
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.
D26056 8-ENG

Become familiar with these terms
before operating the unit.
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per
minute; 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
automatically. The low pressure at
which the motor automatically
restarts is called "cut-in" pressure.
Cut-Out Pressure: When an air
compressor is turned on and begins
to run, air pressure in the air tank
begins to build. It builds to a certain
high pressure before the motor
automatically shuts off - protecting
your air tank from pressure higher
than its capacity. The high pressure
at which the motor shuts off is called
"cut-out" pressure.
Branch Circuit: Circuit carrying
electricity from electrical panel to
outlet.
To Lock Out Power: Place a lock on
the line power switch so no one else
can turn on the power.
mLm.lljiJii_d[o']_ m_
Air compressors should be operated
on not more than a 50% duty cycle.
This means an air compressor that
pumps air more than 50% of one
hour is considered misuse, because
the air compressor is undersized for
the required air demand. Maximum
compressor pumping time per hour is
30 minutes.
Accessories for this unit are available at the store the unit was purchased.
9-ENG D26056

I_..'.,_".]=iLv_I:] i_"d
Contents of Carton
1 - Air Compressor
1 - Parts bag containing:
1 - Operator's Manual
1 - Parts Manual
4 - 5/8" Washers
Tools Required for Assembly
1 - 9/16" socket or open end wrench
1 - electric drill
Unpacking
1. Remove all packaging.
It may be
necessary to brace
or support one side of the outfit
when removing the pallet because
the air compressor will have a
tendency to tip.
2. Remove and discard the (4)
screws and washers holding the
compressor to the pallet.
3. With the help of another person
carefully remove air compressor
from pallet and place on a level
surface.
To Add Oil To Pump
Compressors are
shipped without oil.
A small amount of oil may be
present in the pump upon receipt
of the air compressor. This is due
to plant testing and does not mean
the pump contains oil. Do not
attempt to operate this air
compressor without first adding oil
to the crankcase. Serious damage
can result from even limited
operation unless filled with oil and
broken in correctly. Make sure to
closely follow initial start-up
procedures.
D26056
Multi-Viscosity
motor oils, like
10W 30, should not be used in an air
compressor. They leave carbon
deposits on critical components,
thus reducing performance and
compressor life. Use air compressor
oil onlv.
1. Remove the oil drain plug (B) and
washer (C).
2. Obtain the drain plug extension
(D), from the parts bag.
8,
10-ENG
3. Apply thread sealant tape to the
threads of the drain plug extension
(D).
4. Assemble the washer (C), drain
plug extension (D), and drain plug
(B) as shown in Figure.
5. Tighten securely.
6. Remove the oil fill plug (A).
7. Fill the crankcase with the
recommended oil. NOTE: Use an
air compressor oil such as SAE-30
(API CG/CD heavy duty motor oil).
Under extreme winter conditions
use SAE-20 weightoil.
Replace the oil fill plug (A) and
tighten securely.

II__"hf;_ mlW:'Inl[o_
HOW TO SET UP YOUR UNIT
Location of the Air Compressor
• Locate the air compressor in a
clean, dry, and well ventilated
area.
• Locate the air compressor at
least 12" away from the wall or
other obstructions that will
interfere with the flow of air.
• Locate the air compressor as
close to the main power supply
as possible to avoid using long
lengths of electrical wiring.
NOTE: Long lengths of electrical
wiring could cause power loss to
the motor.
• The air filter must be kept clear
of obstructions which could
reduce air flow to the air
compressor.
Anchoring of the Air
Corn pressor
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 shims (found in
parts bag, if needed)
1. Place the air compressor on on a
solid, level surface.
2. Mark the surface using the holes
in the air compressor feet as a
template.
3. Drill holes in the surface for the
concrete anchors. Install
concrete anchors.
4. Line-up holes in surface with
holes in air compressor feet.
5. Place the (4) washers (not
supplied) between the floor and
air compressor feet. If needed,
solid shims may be placed
between the washers and floor to
evenly distribute weight on all
four feet. See next figure.
3/8" Lag
.....I Screw
.............I (not
..................._supplied)
5/8" Washer .... _ I
(not suppliedi_.[ _ ....................I
ShimUn-_ Surface 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.
11-ENG D26056

Wiring Instructions
_RISK OF
ELECTRICAL
SHOCK. Improper electrical
grounding can result in electrical
shock. The wiring should be done
by a qualified electrician to comply
with national and local electrical
codes.
A qualified electrician needs to knows
the following before wiring:
1. The amperage rating of the
electrical box should be
adequate. Refer to the product
specifications, found in the front
of this manual, for this
information.
2. The supply line should have the
same electrical characteristics
(voltage, cycle, phase) as the
motor. Refer to the motor
nameplate, on side of motor, for
this information.
NOTE: The wiring must be the same
as the motor nameplate voltage plus
or minus 10%. Refer to local codes
for recommended wire sizes, correct
wire size, and maximum wire run;
undersize wire causes high amp draw
and overheating to the motor.
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,
or an equipment-grounding terminal
or lead on the product and comply
with national and local electrical
codes.
Refer to the product specification
found in the front of this manual for
the voltage and minimum branch
circuit requirements.
Air Distribution System
Plastic or PVC pipe
is not designed for
use with compressed air.
Regardless of its indicated
pressure rating, plastic pipe can
burst from air pressure. Use only
metal pipe for air distribution lines.
The next figure represents a typical
air distribution system. The following
are tips to remember when setting up
the air compressor's air distribution
system.
• Use pipe that is the same size as
the air tank outlet. Piping that is
too small will restrict the flow of
air.
If piping is over 100 feet long,
use the next larger size.
Bury underground lines below
the frost line and avoid pockets
where condensation can gather
and freeze. Fill lines with air
pressure before covering to
make sure pipe joints are free
from leaks.
Install a flexible coupling
between the air discharge outlet
and main air distribution line to
allow for vibration.
NOTE: The shut-off valve is not
supplied with this unit. You must
purchsase the shut-off valve
separately.
• A separate regulator is
recommended to control the air
pressure. Air pressure from the
air tank is usually too high for
individual air driven tools.
D26056 12-ENG

FEEDER LINES SLOPE
AIR PLOW _ WITH AIR PLOW
MA_N DISTRIBUTION A_R LINES
Slope pipe in diroction of _ir flow.
Water condensate flows along
bottom of pipe to drain legs,
preventing it from entering feeder
Iines_
i
/
II LUB_ATO_ DRAIN
TRAP
MOISTURE
_ DRAINSEPARATOR
AND TRAP
___A_R PLOW
D_RT i
LEG_ I
FIkT F
A_R DISCHARGE /
LEG VALVE
TYPICAL COMPRESSED
AIR DmSTRIBUTION SYSTEM
DRA_N COCK
VALVE _- __
A_R
COMPRESSOR
13-ENG D26056

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 Tank Pressure Gauge: The tank
Become familiar with these controls pressure gauge indicates the reserve
before operating the unit. air pressure in the tank.
Globe Valve (sold separately):
Opens and closes air discharge valve.
Turn knob counter-clockwise to open
and clockwise to close.
Regulator (sold separately, not
shown): An air pressure regulator or
a separate air transformer which
combines the functions of air
regulation and/or moisture and dirt
removal is recommended for most
applications.
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.
On/Auto/Off Switch: Turn this switch
ON to provide automatic power to the
pressure switch and OFF to remove
power at the end of each use.
Pressure Switch: The pressure
switch automatically starts the motor
when the air tank pressure drops
below the factory set "cut-in"
pressure. It stops the motor when the
air tank pressure reaches the factory
set "cut-out" pressure.
Safety Valve: If the pressure switch
does not shut off the air compressor
at its "cut-out" pressure setting, the
safety valve will protect against high
pressure by "popping out" at its
factory set pressure (slightly higher
than the pressure switch "cut-out"
setting).
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.
D26056 14-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
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.
Check Valve
Pressure Release Valve: The
pressure release valve, located on the
side of the pressure switch, is
designed to automatically release
compressed air from the compressor
head and the outlet tube when the air
compressor reaches "cut-out"
pressure or is shut off. The pressure
release valve allows the motor to
restart freely. When the motor stops
running, air will be heard escaping
from this valve for a few seconds, No
air should be heard leaking when the
motor is running, or continuous
leaking after unit reaches "cut-out"
pressure.
Air Intake Filter (not shown) This
filter is designed to clean air coming
into the pump. This filter must always
be clean and ventilation openings
free from obstructions. See
"Maintenance".
How to Use Your Unit
How to Stop:
1. Set the On/Auto/Off lever to
"OFF",
Before Starting
Break-in Procedure
Serious damage
may result if the
following break-in instructions are
not closely followed.
This procedure is required before the
air compressor is put into service and
when the check valve or a complete
compressor pump has been
replaced.
1. Make sure the On/Auto/Off lever
is in the "OFF" position.
2. Recheck all wiring. Make sure
wires are secure at all terminals
connections. Make sure all
contacts move freely and are not
obstructed.
3. Open the globe valve fully to
permit air to escape and prevent
air pressure build up in the air
tank during the break-in period.
NOTE: The shut-off valve is not
supplied with this unit. You
must purchase the shut-off
valve separately.
4. Move the On/Auto/Off lever to
"ON/AUTO" position. The
compressor will start.
15-ENG D26056

5. Run the compressor for 20
minutes. Make sure the globe
valve is open and there is
minimal air pressure build-up in
tank.
6. Check all air line fittings and
connections/piping for air leaks
by applying a soap solution.
Correct if necessary. NOTE:
Minor leaks can cause the air
compressor to overwork,
resulting in premature breakdown
or inadequate performance.
7. Check for excessive vibration.
Readjust or shim air compressor
feet, if necessary.
8. After 20 minutes, close the globe
valve. The air receiver will fill to
"cut-out" pressure and the motor
will stop.
Before Each Start-Up:
1. Place On/Auto/Off lever to
"OFF".
2. Close the globe valve.
3. Attach hose and accessories.
NOTE: A regulator MUST be
installed when using accessories
rated at less than 175 PSI.
Too much air
pressure causes a
hazardous risk of bursting. Check
the manufacturer's maximum
pressure rating for air tools and
accessories. The regulator outlet
pressure must never exceed the
maximum pressure rating.
How to Start
1. Turn the On/Auto/Off lever to
"AUTO" and allow tank pressure
to build. Motor will stop when
tank pressure reaches "cut-out"
pressure.
2. When the tank pressure reaches
"cut-out" pressure open the
globe valve.
IMPORTANT: When using regulator
and other accessories refer to the
manufacturer-s instructions.
NOTE: 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 compressor near the spray
area.
D26056 16-ENG

Customer Responsibilities
Before Every Every Every Every Every
each 8 40 100 160 500 Yearly
use hours hours hours hours hours
Check Safety Valve •
Drain Tank •
Check Oil •
Change Oil 0202
Unusual Noise and/or
Vibration •
Air Filter O1
Drive Belt-Condition •
Motor Pulley/Flywheel alignment •
Air compressor pump intake •
and exhaust valves
Inspect air lines and fittings •
for leaks
Head Bolts - Check the torques of the head bolts after the first fivehours of operation.
1- more frequent in dusty or humid conditions
2- more frequent if humidity or operating conditions are extreme.
Unit cycles automatically when power is on. When
performing maintenance, you may be exposed to voltage
sources, compressed air, or moving parts. Personal injuries can occur.
Before performing any maintenance or repair, disconnect power source
from the compressor and bleed off all air pressure.
To ensure efficient operation and longer life of the air compressor outfit, a
routine maintenance schedule should be prepared and followed. The following
routine maintenance schedule is geared to an outfit in a normal working
environment operating on a daily basis. If necessary, the schedule should be
modified to suit the conditions under which your compressor is used. The
modifications will depend upon the hours of operation and the working
environment. Compressor outfits in an extremely dirty and/or hostile
environment will require a greater frequency of all maintenance checks.
NOTE: See "Operation" section for the location of controls.
To Check Safety Valve
If the safety valve
does not work
properly, over-pressurization may
occur, causing air tank rupture or
an explosion.
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.
17-ENG D26056

To Drain Tank
NOTE: Operation of the air
compressor will cause condensation
to build up in the air tank. Always
drain tank on a washable surface or
in a suitable container to prevent
damaging or staining surfaces.
1. Set the On/Auto/Off lever to
"OFF".
2. Close the globe valve.
3. Remove the air tool or
accessory.
4. Open the globe valve and allow
the air to slowly bleed from the
air tank until tank pressure is
approximately 20 psi.
5. Close the globe valve.
6. Drain water from air tank by
opening drain valve (counter-
clockwise) 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 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, then
reinstalled.
Oil
NOTE: Use a air compressor oil such
as SAE-30 (API CG/CD heavy duty
motor oil. Under extreme winter
conditions use SAE-20 weight oil.
NOTE: Crankcase oil capacity is
approximately 60 fluid ounces (1.8 I).
Checking
1. The oil level should be to the
middle of the sight glass (C).
2. If needed remove oil fill plug (A)
and slowly add oil until it reaches
the middle of the sight glass.
Changing
1. Remove the oil fill plug (A).
2. Remove the oil drain plug (B) and
drain oil into a suitable container.
3. Replace the oil drain plug (B) and
tighten securely
4. Sowly add compressor oil until
the oil level is in the middle of the
sightglass (C). NOTE: When
filling the crankcase, the oil flows
very slowly into the pump. If the
oil is added too quickly, it will
overflow and appear to be full.
Overfilling with oil
will cause
premature compressor failure. Do
not overfill.
5. Replace oil fill plug (A) and
tighten securely.
D26056 18-ENG

Air Filter -Inspection and
Replacement
Hot surfaces. Risk
of burn.
Compressor heads are exposed
when filter cover is removed.
Allow compressor to cool prior to
servicing.
A dirty air filter will not allow the
compressor to operate at full
capacity. Keep the air filter clean at
all times.
1. Remove the air filter cover.
2. Remove the air filter from filter
cover.
IMPORTANT: Do not operate the
compressor with the air filter
removed.
3. Place new air filter into filter
cover. Refer to the "Repair Parts"
for the correct part number.
4. Replace air filter cover and lock
into place.
Belt -Replacement
(Refer to the Outfit Parts Manual
for replacement belt part number.)
Serious injury or
damage may occur
if parts of the body or loose items
get caught in moving parts. Never
operate the outfit with the belt
guard removed. The belt guard
should be removed only when the
AIR compressor power is
disconnected.
1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Remove the belt guard.
3. Mark pump position on saddle.
4. Loosen the motor mounting
screws and slide the motor
toward the air compressor.
5. Remove the belt and replace
with a new one.
6. See the "Adjust Belt Tension"
before tightening motor
mounting screws.
Adjusting Belt Tension
1. Slide motor into original position,
line the motor up with the mark
made earlier on saddle.
2. Tighten two outside motor
mounting screws enough to hold
the motor in place for checking
pulley and flywheel alignment.
3. The belt should deflect 3/16" at
midway between the pulley and
the flywheel when a 5 pound
weight is applied at the midway
point.
4. When proper belt tension is
achieved, tighten all four motor
mounting screws. See Parts
manual for torque specifications.
NOTE: Once the engine pulley has
been moved from its factory set
location, the grooves of the
flywheel and pulley must be aligned
to within 1/16" to prevent excessive
belt wear. Verify the alignment by
performing the following Pulley and
Flywheel -Alignment.
19-ENG D26056

Motor Pulley/Flywheel
Alignment
NOTE: Once the motor pulley has
been moved from its factory set
location, the grooves of the flywheel
and pulley must be aligned to within
1/16" to prevent excessive belt wear.
The air compressor flywheel and
motor pulley must be in-line (in the
same plane) within 1/16" to assure
belt retention within flywheel belt
grooves. To check alignment,
perform the following steps:
1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Remove belt guard
3. Place a straightedge against the
outside of the flywheel and the
motor drive pulley.
LBELT _O'F Q,_:ULL,_Y
A1 t,2 IN_SU}_I 8TRNGHT
BI_8_{w_u_) EDGE
4. Measure the distance between
the edge of the belt and the
straightedge at points A1 and A2
in figure. The difference
between measurements should
be no more than 1/16".
5. If the difference is greater or less
than 1/16" loosen the set screw
holding the motor drive pulley to
the shaft and adjust the pulley's
position on the shaft until the A1
and A2 measurements are within
1/16" of each other.
6. Tighten the motor drive pulley
set screw. See Parts manual for
torque specifications.
7. Visually inspect the motor drive
pulley to verify that it is
perpendicular to the drive motor
shaft. Points B1 and B2 of Figure
should appear to be equal. If
they are not, loosen the setscrew
of the motor drive pulley and
equalize B1 and B2, using care
not to disturb the belt alignment
performed in step 2.
8. Retighten the motor drive pulley
setscrew. See Parts manual for
torque specifications.
9. Reinstall belt guard.
Air Compressor Pump Intake
and Exhaust Valves
Once a year have a Trained Service
Technician check the air compressor
pump intake and exhaust valves.
Inspect Air Lines and Fittings
for Leaks
1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Apply a soap solution to all air
line fittings and
connections/piping.
3. Correct any leaks found.
IMPORTANT: Even minor leaks can
cause the air compressor to
overwork, resulting in premature
breakdown or inadequate
performance.
Air compressor Head Bolts -
Torquing
The air compressor pump head bolts
should be kept properly torqued.
Check the torques of the head bolts
after the first five hours of operation.
Retighten if necessary. See Parts
manual for torque specifications.
D26056 20-ENG