Craftsman 919.184190 User manual

Owner's Manual
ICRRFTSMRN1
Oil Lubricated
Single Stage
Vertical Stationary
AIR COMPRESSOR
Model No.
919.184190
• Safety Guidelines
•Assembly
• Operation
• Maintenance
• Service and Adjustments
• Troubleshooting
• Repair Parts
•Espa_ol
CAUTION; Read the Safety Guidelines
and All Instructions Carefully Before
Operating.
Sears, Roebuck and Co., Hoffman Estates, IL 60170 U.S.A.
visit our craftsman website: www.sears.com/craftsman
D24917 Rev. 2 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 .......................................... 11-13
OPERATION ............................................ 14-16
MAINTENANCE ......................................... 17-19
SERVICE AND ADJUSTMENTS ............................ 20-21
STORAGE ................................................ 22
TROUBLESHOOTING GUIDE .............................. 24-27
REPAIR PARTS ......................................... 28-31
ESPAI_IOL .............................................. 32-57
HOW TO ORDER REPAIR PARTS ...................... back cover
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FULL ONE YEAR WARRANTY AIR COMPRESSOR
If this product fails due to a defect in material or workmanship within one
year from the date of purchase, return it to your nearest Sears Service
Center in the United States, and it will be repaired 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
D24917 2-ENG

Model No. 919-184190
Max. Developed HP 7.0
Bore 2.875"
Stroke 2.0"
Voltage-Single Phase 240
Minimum Branch Circuit Requirement 15 amps
Fuse Type Time Delay
Air Tank Capacity 60 gallons
Approximate Cut-in Pressure 120
Approximate Cut-out Pressure 150
SCFM @ 40 psig 12.4
SCFM @ 90 psig 10.2
Refer to Glossary for abbreviations.
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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 symbols.
Indicates an
imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a
potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
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.
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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 D24917

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.
I:V:YJ:I;{m]
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
3roduct 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.
D24917 4-ENG

I: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.
I:V;YJ;I;tm]
WARNING: Risk from Flying Objects
WHAT CAN HAPPEN HOW TO PREVENTIT
The compressed air stream can cause
soft tissue damage to exposed skin and
can propel dirt, chips, loose particles,
and small objects at high speed,
resulting in property damage or personal
injury.
Always wear ANSI Z87.1 approved safety
glasses with side shields when using the
compressor.
Never point any nozzle or sprayer
toward any part of the body or at other
people or animals.
Always turn the compressor oft and
bleed pressure from the air hose and tank
before attempting maintenance, attaching
tools or accessories.
5-ENG D24917

; V;Ir_';lI-1m]
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.
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.
D24917 6- ENG

; V;Ir_';lI-1m]
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.
; V;I,_';II'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
com into contact with you or your removed.
clothing.
Attempting to operate compressor with Any repairs required on this product
damaged or missing parts or attempting should be performed by authorized
to repair compressor with protective service center personnel.
shrouds removed can expose you to
moving parts and can result in serious
injury.
I:V;YJ;I;1m]
WARNING: RISK OF SERIOUS INJURY OR PROPERTY
DAMAGE WHEN TRANSPORTING COMPRESSOR
(Fire, Inhalation, Damage to VehicleSurfaces)
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 D24917

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.
D24917 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.
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", 5/16", or 3/8" OR
1/2" inside diameter in various
lengths
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This 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
for a 50% duty cycle.
9-ENG D24917

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 air
compressor 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.
Adding 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.
NOTE: Use an air compressor oil
such as Sears item number 9-16426
or SAE-20 (API CG/CD) heavy duty
motor oil. Under extreme winter
conditions use SAE-10 weight oil.
To Add Oil
Drain tank to
release air pressure
before removing the oil fill cap or
oil drain plug.
1. Place unit on a level surface.
2. Remove oil fill plug (A) and
slowly add compressor oil until it
is even with the top of the oil fill
hole. NOTE: Do not allow oil to
be lower than 3/8" (6 threads)
from the top at any time. 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.
NOTE: Crankcase oil capacity is
approximately 16 fluid ounces.
3. Replace oil fill plug.
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.
D24917 10- ENG

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HOW TO SET UP YOUR
UNIT
Air Compressor Location
• 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
Compressor
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 (found in parts
bag)
shims (if needed)
1. Place the air compressor on a
solid, level surface.
2. Mark the surface using the holes
in the air compressor feet as a
template.
3.
4.
5.
Drill holes in the surface for the
concrete anchors. Install
concrete anchors.
Line up holes in surface with
holes in air compressor feet.
Place the (4) washers (supplied)
between the floor and air
compressor feet. If needed, solid
shims may be placed between
the washers and floor to evenly
distribute weight on all four feet.
See next figure.
3/8" Lag
I Screw
......_(not
5/8 Washer ..... _ supplied)
(supplied) L_
_" Surface Line
Shim Under
Washer Concrete Anchor
(not supplied) (not supplied)
6. Place the (4) 3/8" lag screws
through the air compressor feet,
washers, shims, and into the
anchors.
7. Torque 3/8" lag screws to 7-10
ft.-Ibs.
Wiring Instructions
RISK OF
ELECTRICAL
SHOCK. Improper electrical
grounding can result in electrical
shock. The wiring should be done
by a qualified electrician.
A qualified electrician needs to know
the following before wiring:
1. The amperage rating of the
electrical box should be
adequate. Refer to the
Specification Table, in this
manual, for this information.
11-ENG D24917

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 supply voltage must be
the same as the motor nameplate
voltage plus or minus 10%. Refer to
local codes for correct wire size and
maximum wire run; undersize wire
causes high amp draw and
overheating of 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.
Grounding location is clearly
indicated on compressor.
Voltage and Circuit Protection
Refer to the Specification Table for
the voltage and minimum branch
circuit requirements.
IMPORTANT: This air compressor will
operate on a 15 amp circuit only if
the following conditions are met.
1. Voltage supply through branch
circuit is 15 amps.
2. Circuit is not used to supply any
other electrical needs (lights,
appliances, etc.).
3. 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 marked
_U _,
If any of the above conditions cannot
be met, or if operation of the
compressor repeatedly causes
interruption of the power, it may be
necessary to operate it from a 20
amp circuit.
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.
D24917 12-ENG

Install a flexible coupling
between the air discharge outlet
and main air distribution line to
allow for vibration.
A separate regulator is
recommended to control the air
pressure. Air pressure from the
air tank is usually too high for
individual air driven tools.
FEEDER LINES SLOPE
AiR FLOW _ WITH AIR FLOW
-. I
--...
MA_N D_STR_RUT!ON AIR LINES
Slope pipe in direction of air flow
Water condensate flows along
bottom of pipe to drain legs,
preventing it from entering feeder
lines_
/
DRAIN
TRAP
MOISTURE
DRAIN SEPARATOR
AND TRAP
_i__ j___AIRFLOW
D RT _
LEG _ i
FIkT R
FLEXIBLE _
OOUPUNG .
A_R D_SCRARGE /
LEG VAL&_E
TYPICAL COMPRESSED
AIR DmSTRJBUTION SYSTEM
DRAIN COCK
VALVE -- _
AIR
COMPRESSOR
13- ENG D24917

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,
Tank Pressure Gauge: The air tank
pressure gauge indicates the reserve
air pressure in the air tank.
Globe Valve: Opens and closes air
discharge valve. Turn knob counter-
clockwise to open and clockwise to
close.
Drain Valve: The drain valve is
located at the base of the air tank
and is used to drain condensation at
the end of each use.
On/Auto/Off Switch: Turn this switch
ON/AUTO 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. The pressure switch 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.
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.
D24917 14-ENG

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.
VaIve
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 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 First Start-up
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 the
first time and when the check valve
or a complete compressor pump has
been replaced,
Break-in Instructions
1.
2.
Make sure the On/Auto/Off lever
is in the "OFF" position,
Recheck all wiring. Make sure
wires are secure at all terminals
connections. Make sure all
contacts move freely and are not
obstructed,
3. Open the globe valve fully to
permit air to escape and prevent
air pressure build-up in the air
tank during the break-in period,
4. Move the On/Auto/Off lever to
"ON/AUTO" position. The
compressor will start.
5. Run the compressor for 20
minutes. Make sure the globe
valve is open and check tank
pressure gauge for minimal air
pressure build-up in air tank.
6. Check all air line fittings and
connections/piping for air leaks
by applying a soap solution to
them, Bubbles will indicate a
leak. 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.
15-ENG D24917

8, After 20 minutes, close the globe
valve.The air tank 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 120 PSI.
Too much air
pressure causes a
hazardous risk of the air tank
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 air tank
pressure to build. Motor will
stop when air tank pressure
reaches "cut-out" pressure.
2. When the air 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.
D24917 16-ENG

Customer Responsibilities
Before Daily or Every Every Every Every Yearly
each after 8 40 100 160
use each hours hours hours hours
use
Check Safety Valve •
Drain Air Tank •
Check Oil •
Change Oil •
Listen for Unusual
Noise and/or •
Vibration
Check Air Filter • (1)
Check Drive Belt •
Condition
Check Motor Pulley/ •
Flywheel alignment
Check Air
compressor pump •
intake and exhaust
valves
Inspect air lines and •
fittings for leaks
1- more frequent in dusty or humid conditions
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 air
compressor, a routine maintenance
schedule should be prepared and
followed. The following 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
compressor is used. The
modifications will depend upon the
hours of operation and the working
environment. Air compressors in an
extremely dirty and/or hostile
environment will require a greater
frequency of all maintenance checks.
NOTE: See "Operation" section for
the location of controls.
17-ENG D24917

To Check Safety Valve
If the safety valve
does not work
properly, over-pressurization may
occur, causing air tank rupture or
explosion and possible serious
injury.
1. Before starting compressor, pull
the ring on the safety valve to
make sure that the safety valve
operates freely. Ifthe valve is
stuck or does not operate
smoothly, it must be replaced
with the same type of valve.
To Drain Air tank
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 air 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
and possible serious injury.
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
Drain air tank to
release air
pressure before removing the oil fill
cap or oil drain plug.
NOTE: Use air compressor oil such
as SAE-20 (API CG/CD) heavy duty
motor oil. Under extreme winter
conditions use SAE-10 weight oil. Oil
capacity is approximately 16 fluid
ounces.
Checking
1. Remove the oil fill plug (A). The
oil level should be even with the
top of the fill hole and no lower
than 6 threads from the top of fill
hole.
2. If needed, slowly add oil until it
reaches the top of fill hole.
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. Slowly add compressor oil until it
is even with the top of the oil fill
hole. 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.
5. Replace oil fill plug (A) and
tighten securely.
D24917 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.
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. Unplug air compressor from
power source.
2. Remove belt guard.
3. Place a straightedge against the
outside of the flywheel and the
motor drive pulley.
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. Torque the motor drive pulley set
screw to 70-80 in.-Ibs.
7. Visually inspect the motor drive
pulley to verify that it is
perpendicular to the drive motor
shaft. Points B1 and B2 in figure
above 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 4.
8. Retighten the motor drive pulley
set screw to 70-80 in.-Ibs.
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 the air compressor on to
inspect for air leaks.
2. Apply a soap solution to all air
line fittings and
connections/piping. Bubbles will
indicate a leak.
3. Correct any leaks found.
IMPORTANT: Even minor leaks can
cause the air compressor to
overwork, resulting in premature
breakdown or inadequate
performance.
19-ENG D24917

Unit cycles
automatically when
power is on. When performing
adjustments or repair, you may be
exposed to voltage sources,
compressed air or moving parts.
Personal injuries can occur. Before
performing any adjustments or
repair, unplug the compressor and
bleed off all air pressure.
ALL SERVICE AND REPAIR
OPERATIONS NOT DESCRIBED IN
THIS MANUAL MUST BE
PERFORMED BY A TRAINED
SERVICE TECHNICIAN.
Before servicing:
•Unplug or disconnect electrical
supply to the air compressor.
•Bleed air tank of pressure.
•Allow the air compressor to
cool.
To Replace or Clean Check
Valve
1. Release all air pressure from air
tank. See "To Drain Air tank" in
the Maintenance section.
2. Unplug unit.
3. Using an adjustable wrench,
loosen outlet tube nut at air tank
and pump. Carefully move outlet
tube away from check valve.
4. Using an adjustable wrench,
loosen pressure relief tube nut at
air tank and pressure switch.
Carefully move pressure relief
tube away from check valve.
5. Unscrew the check valve (turn
counterclockwise) using a 7/8 "
open end wrench. Note the
orientation for reassembly.
6. 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 it in the
closed position; if valve disc is
not moving freely the check valve
needs to be cleaned or replaced.
position
nothing is
visible.
In closed position
disc is visible.
7. Clean or replace the check valve.
A solvent, such as paint or
varnish remover can be used to
clean the check valve.
8. Apply sealant to the check valve
threads. Reinstall the check valve
(turn clockwise).
9. Replace the pressure release
tube. Tighten nuts.
10. Replace the outlet tube and
tighten nuts.
11. Perform the Break-in Procedure.
See "Break-in Procedure" in the
Operation section.
D24917 20-ENG