Craftsman 919.195410 User manual

Owner's Manual
ICRAFTSMFIN°I
Oil Lubricated
Single Stage
Horizontal Portable
AiR COMPRESSOR
Model No.
919.195410
=Safety Guidelines
=Assembly
= Operation
=Maintenance
=Service and Adjustments
=Troubleshooting
= Repair Parts
=Espa5ol
CAUT|ON, 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
D24910 Rev. 1 1/18/03

WAR RANTY ............................................. 2
SPECiFiCATiON CHART .................................... 3
SAFETY GUiDELiNES .................................... 3-8
GLOSSARY .............................................. 9
ACCESSORIES .......................................... 9
DUTY CYCLE ............................................ 9
ASSEMBLY .......................................... 10-12
iNSTALLATiON ........................................ 12-13
OPERATION .......................................... 14-16
MAINTENANCE ....................................... 17-19
SERVICE AND ADJUSTMENTS ........................... 20-22
STO RAGE .............................................. 23
TROUBLESHOOTING GUIDE ............................ 24-27
REPAIR PARTS ....................................... 28-31
ESPA_IOL ............................................ 32-57
HOW TO ORDER REPAIR PARTS .................... Back Cover
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, IL 60179
D24910 2- ENG

Model No. 919-195410
Max. Developed HP 6.0
Bore 2.875"
Stroke 2.0"
Voltage-Single Phase 120/240
Minimum Branch Circuit Requirement 15 amps
Fuse Type Time Delay
Air Tank Capacity 25 gallons
Approximate Cut-in Pressure 120
Approximate Cut-out Pressure 150
SCFM @ 40 psig 8.6
SCFM @ 90 psig 6.8
Refer to Glossary for abbreviations.
This manual contains information that is important for you to know and under-
stand. This information relates to protecting YOUR 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.
_lndicates an immi-
nently hazardous sit-
uation which, if not avoided, will
result in death or serious injury.
_lndicates a potential-
ly hazardous situa-
tion which, if not avoided, could
result in death or serious injury.
_lndicates a potential-
ly hazardous situa-
tion which, if not avoided,
result in minor or moderate iniur_
_Used without the
safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may
result in ro eft dama e.
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 repro-
ductive 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 venti-
lated 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 D24910

_t Save these instructions _O
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.
What Could Happen
it is normal for electrical contacts within
the motor and pressure switch to spark.
WARNING: Risk of explosion or fire
How To Prevent it
Always operate the compressor in a well
ventilated area free of combustible
materials, gasoline, or solvent vapors.
if electrical sparks from compressor
come into contact with flammable
vapors, they may ignite, causing fire or
explosion.
Restricting any of the compressor venti-
lation openings will cause serious over-
heating and could cause fire.
Unattended operation of this product
could result in personal injury or prop-
erty damage. To reduce the risk of fire,
do not allow the compressor to operate
unattended.
If spraying flammable materials, locate
compressor at least 20 feet away from
spray area. An additional length of 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 inches away
from any wall or obstruction that would
restrict the flow of fresh air to the ventila-
tion openings.
Operate compressor in a clean, dry well
ventilated area. Do not operate unit
indoors or in any confined area.
Always remain in attendance with the
product when it is operating.
Always disconnect electrical power by
moving pressure switch lever to the off
position and drain tank daily or after
each use.
D24910 4- ENG

WARNING: Risk of Bursting I_1
Air Tank: The following conditions could lead to a weakening of the tank, and result
in aviolent tank explosion and could cause property damage or serious injury.
1.
What Could Happen
Failure to properly drain con-
densed 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 acces-
sories, 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 immedi-
ately with a new tank or replace the entire
compressor.
Never drill into, weld, or make any modF
fications to the tank or its attachments.
The tank is designed to withstand specific
operating pressures. Never make adjust-
merits 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 recommenda-
tion 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.
WARNING: Risk from Flying Objects ._a
WHAT CAN HAPPEN HOW TO PREVENT iT
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, result-
ing 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 off and
bleed pressure from the air hose and tank
before attempting maintenance, attaching
tools or accessories.
5- ENG D24910

WARNING: Risk of Electrical Shock
WHAT CAN HAPPEN HOW TO PREVENT IT
Your air compressor is powered by Never operate the compressor outdoors
electricity. Like any other electrically when it is raining or in wet conditions.
powered device, If it is not used properly Never operate compressor with protec-
it may cause electric shock, tive covers removed or damaged.
Repairs attempted by unqualified per=
sonnel 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.
Any electrical wiring or repairs required
on this product should be performed by
authorized service center personnel in
accordance with national and local electri-
cal codes.
Make certain that the electrical circuit
to which the compressor is connected
provides proper electrical grounding,
correct voltage and adequate fuse pro=
tection.
WARNING: Risk to Breathing
WHAT CAN HAPPEN HOW TO PREVENT IT
The compressed air directly from your
compressor is not safe for breathing.
The air stream may contain carbon
monoxide, toxic vapors, or solid partF
cles from the tank. Breathing these con=
taminants can cause serious injury or
death.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides,
weed killers, may contain harmful vapors
and poisons.
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 breath-
ing, 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 aH applica-
ble local and federal codes prior to
human consumption.
Work in an area with good cross ventF
lation. 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.
D24910 6- ENG

WARNING: RISK OF BURNS I ,_., I
WHAT CAN HAPPEN HOW TO PREVENT iT
Touching exposed metal such as the
compressor head or outlet tubes, can
result in serious burns.
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.
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
corn into contact with you or your cloth- removed.
ing.
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 mov-
ing parts and can result in serious injury.
WARNING: RiSK OF FALLING
WHAT CAN HAPPEN
A portable compressor can faU from a
table, workbench, or roof causing dam=
age to the compressor and could result
in serious injury or death to the opera=
tot.
HOW TO PREVENT IT
Always operate compressor in astable
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.
7- ENG D24910

WARNING: RISK OF SERIOUS iNJURY OR PROPERTY DAM-
AGE WHEN TRANSPORTING COMPRESSOR
(Fire, Inhalation, Damage to Vehicle Surfaces)
WHAT CAN HAPPEN
oil can leak or spill and could result in
fire or breathing hazard; serious injury or
death can result, oil leaks will damage
carpet, paint or other surfaces in vehicles
or trailers.
HOW TO PREVENT IT
Always place COMPRESSOR on a pro-
tective mat when transporting to protect
against damage to vehicle from leaks.
Remove COMPRESSOR from vehicle
immediately upon arrival at your destina-
tion.
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 compres-
sor at all times.
Do not operate the product when
fatigued or under the influence of alco=
hol or drugs. Stay alert at all times.
Never defeat the safety features of this
product.
Equip area of operation with afire extin-
guisher.
Do not operate machine with missing,
broken, or unauthorized parts.
D24910 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 deliv-
ery.
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 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 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:l/4", 3/8" or 1/2" inside
diameter in various lengths
Refer to the selection chart located
on the unit to select the tools this unit
is capable of powering.
This air compressors should be oper-
ated 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 D24910

Contents of Carton
1 - Air Compressor
2- Wheels
2 - Shoulder Bolts, 3/8-16
2 - Hex Nuts, 3/8-16
1- Handle
1 - Handle Grip
2 - Cap Screws
2 - 1/4-20 Hex Nuts
2 - Retainer Clips
2 - Flat Washers
2 - Rubber Bumpers
2 - Screws, 1/4-20 x .75
Tools Required for Assembly
1 - 9/16" socket or open end wrench
1 - 1/2" socket or open end wrench
Unpacking
Remove unit from carton and discard
all packaging. NOTE: Save all parts
bags.
To install Handle
The wheels and
handle do not pro-
vide adequate clearance, stability,
or support for pulling the unit up
and down stairs or steps. The unit
must be lifted or pushed up a
ramp. Do not lift the unit by the
manifold assembly; the unit could
be damaged.
1. To make installation easier, sub-
merge handle grip into warm
soapy water. Remove handle
grip from soapy water and slide
onto handle.
3,
2,
D24910
4,
Insert the open ends of the han-
dle under the saddle. Before
attaching handle, you may have
to pull the open ends of the han-
dle apart so they fit tightly
against the side of the saddle.
Looking in from the open end of
the saddle, position the handle
toward the two bent tabs, on the
inside walls of the saddle.
10- ENG
TABS SADDLE OF HANDLE
Slowly push the open ends of
the handle onto both tabs at the
same time. Continue pushing the
handle into the saddle until the
holes on the side of the saddle
and handle are in line.
%.Z_
r _ HANDLE
OPEN END HOLE
BENT TAB OF HANDLE
Guide the straight end of each
retaining clip through the saddle
hole and both handle holes.
CLIPS
ON TABS

5.
6.
Rotate each retaining clip clock-
wise and press down until it
snaps into place over the handle.
If the handle has excessive
movement, it is improperly
installed. Check the following.
A. Are both tabs inside the
handle (Step #3)?
B. Does each clip pass through
both the saddle and handle
(Step #4)?
To Assemble Wheels
It will be necessary
to brace or support
one side of the air compressor
when installing the wheels because
the compressor will have a tenden-
cy to tip.
1. Attach wheels with shoulder
bolts and nuts as shown.
2. Tighten securely. NOTE: The air
compressor will sit level if the
wheels are properly installed.
The wheels and
handle do not pro-
vide adequate clearance, stability
or support for pulling the unit up
and down stairs or steps. The unit
must be lifted, or pushed up a
ramp.
Assemble Rubber Feet
1. Attach rubber feet with the
screws, washers and nuts pro-
vided as shown in figure below.
2. Tighten securely.
Nut
Wheel
To Add Oil To Pump
Compressors are
shipped without oil.
A small amount of oil may be pres-
ent 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 fol-
low initial start-up procedures.
Use air compressor
oil only. Multi=
Viscosity motor oils, like 10W 30,
should not be used in an air corn=
pressor. They leave carbon
deposits on critical components,
thus reducing performance and
compressor life.
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 con-
ditions use SAE-10 weight oil.
11- ENG D24910

To Add Oil
I_ 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 slow-
ly 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.
Air Compressor Location
® Locate the air compressor in a
clean, dry, and well ventilated
area.
The air compressor should be
located at least 12" away from
the wall or other obstructions
that will interfere with the flow of
air.
® The air filter and flywheel must
be kept clear of obstructions
which could reduce air flow to
the air compressor.
® The air compressor requires
fresh air flow for proper cooling.
DO NOT ALLOW THE COM-
PRESSOR TO GET WET.
GROUNDING INSTRUCTIONS
RISK OF ELECTRI-
CAL SHOCK. In
the event of a short circuit, ground-
ing reduces the risk of shock by
providing an escape wire for the
electric current. This air compres-
sor 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). The plug must be used with
an outlet that has been installed and
grounded in accordance with all local
codes and ordinances.
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 illustra-
tion.
Gr_.
Grounded
Outlets
D24910 12- ENG

3. Inspect the plug and cord before
each use. Do not use if there are
signs of damage.
4. If these grounding instructions
are not completely understood,
or if in doubt as to whether the
compressor is properly ground-
ed, have the installation checked
by a qualified electrician.
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 over-
heating.
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 Parts Manual for the volt-
age and minimum branch circuit
requirements.
Certain air compressors can be oper-
ated on a 15 amp circuit if the follow-
ing 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. Extension cords comply with
specifications.
4. Circuit is equipped with a 15
amp circuit breaker or 15 amp
time delay fuse. NOTE: If com-
pressor 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 interrup-
tion of the power, it may be neces-
sary to operate it from a 20 amp cir-
cuit. If operating from a 20 amp cir-
cuit, it is not necessary to change the
cord set.
13- ENG D24910

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. On/Auto/Off
Switch
Connect
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" pres-
sure. 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 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.
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 connections simple and easy.
Drain Valve: The drain valve is locat-
ed at the base of the air tank and is
used to drain condensation at the
end of each use.
Valve
D24910 14- ENG

Cooling System (not shown): This
compressor contains an advanced
design cooling system. At the heart
of this cooling system is an engi-
neered fan. It is perfectly normal for
this fan to blow air through the vent
holes in large amounts. You know
that the cooling system is working
when air is being expelled.
Air Compressor Pump (not shown):
Compresses air into the air tank.
Working air is not available until the
compressor has raised the air tank
pressure above that required at the
air outlet.
Check Valve: When the air compres-
sor is operating, the check valve is
"open", allowing compressed air to
enter the air tank. When the air com-
pressor reaches "cut-out" pressure,
the check valve "closes", allowing air
pressure to remain inside the air tank.
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" pres-
sure 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.
Pressure
Release
Valve
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 leverto
"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 and
when the check valve or a complete
compressor pump has been
replaced.
Break-in instructions
1. Make sure the On/Auto/Off lever
is in the "OFF" position.
NOTE: If quick connect is installed,
pull coupler back until it clicks to pre-
vent air from escaping through the
quick connect.
2. Plug the power cord into the cor-
rect branch circuit receptacle.
(Refer to Voltage and Circuit
Protection paragraph in the
Installation section of this manu-
al.)
3. Open the drain valve fully (coun-
terclockwise) 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 com-
pressor will start.
5. Run the compressor for 20 min-
utes. Make sure the drain valve is
open and there is minimal air
pressure build-up in tank.
15- ENG D24910

6. After 20 minutes, close the drain
valve (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 On/Auto/Off lever to
"OFF".
2.
3.
Pull regulator knob out, turn
counterclockwise until it stops.
Push knob in to lock in place.
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.
Too much air pres-
-- sure causes a haz-
ardous risk of bursting. Check the
manufacturer's maximum pressure
rating for air tools and accessories.
The regulator outlet pressure must
never exceed the maximum pres-
sure 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. 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. The compressor is
ready for use.
NOTE: Always operate the air com-
pressor in well-ventilated areas free
of gasoline or other combustible
vapors. If the compressor is being
used to operate a sprayer DO NOT
place near the spray area.
D24910 16- ENG

Customer Responsibilities
Before Daily or Every Every Every Every
each after 8 40 100 160 Yearly
use each hours hours hours hours
use
Check Safety Valve •
Drain Tank •
Oil Leaks •
Check Oil •
Change Oil •
Unusual Noise
and/or Vibration •
Air Filter • (1)
Drive Belt ®
Condition
Motor Pulley/ •
Flywheel alignment
Air compressor pump
intake and exhaust
valves ®
1- more frequent in dusty or humid conditions
Unit cycles auto-
-- matically when
power is on. When performing
maintenance, you may be exposed
to voltage sources, compressed
air, or moving parts. Personal
injuries can occur. Before perform-
ing any maintenance or repair, dis-
connect 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 fol-
lowed. The following routine mainte-
nance schedule is geared to an air
compressor in a normal working envi-
ronment 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 environ-
ment will require a greater frequency
of all maintenance checks.
NOTE: See "Operation" section for
the location of controls.
17- ENG D24910

To Check Safety Valve
if the safety valve
does not work
properly, over-pressurization may
occur, causing air tank rupture or
an explosion.
1. 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
1. Set the On/Auto/Off lever to
"OFF".
2. Pull the regulator knob out and
turn clockwise to set the outlet
pressure to zero.
3. Remove the air tool or accesso-
ry.
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
opening drain valve (counter-
clockwise) on bottom of tank.
Water will con-
dense in the air
tank. if not drained, water will cor-
rode and weaken the air tank caus-
ing a risk of air tank rupture.
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, and
reinstalled.
Oil
Drain tank to
release air pres=
sure before removing the oil fill cap
or oil drain plug.
Checking
1. Place unit on a level surface.
2. 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.
NOTE: Use an air compressor oil
such as SAE-20 (API CG/CD heavy
duty motor oil. Under extreme winter
conditions use SAE-10 weight oil.
Changing
1. Place unit on a level surface.
2. Remove the oil fill plug (A).
3. Remove the oil drain plug (B) and
drain oil into a suitable container.
4. Replace the oil drain plug (B) and
tighten secure.
NOTE: Use an air compressor oil
such as SAE-20 (API CG/CD heavy
duty motor oil. Under extreme winter
conditions use SAE-10 weight oil.
5. Slowly fill crankcase to the top of
the fill hole. Crankcase capacity
is 16 fluid ounces (473.2 ml).
6. Replace oil fill plug (A) and tight-
en securely
D24910 18- ENG

Air Filter inspection and
RepJacement
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 com-
pressor to operate at full capacity.
Keep the air filter clean at all times.
1. Remove the air filter cover.
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".
BELT MOTOR PULLEY I
I
..... p J
/
AI= A2 (MEASURED) STRAIGHT
B1= B2 (VISUAL) EDGE
2. Remove the air filter from filter 5.
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" 6.
for the correct part number.
4. Replace air filter cover and lock 7.
into place.
8.
9.
Motor Pulley/Flywheel
Alignment
NOTE: Once the motor pulley has
been moved from its factory set loca-
tion, 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, per-
form 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.
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.
Torque the motor drive pulley set
screw to 70-80 in.-Ibs.
Visually inspect the motor drive
pulley to verify that it is perpen-
dicular 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.
Retighten the motor drive pulley
setscrew to 70-80 in.-Ibs.
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.
19- ENG D24910

Unit cycles auto-
matically when
power is on. When doing
Maintenance, you may be exposed
to voltage sources, compressed air
or moving parts. Personal injuries
can occur. Before performing any
Maintenance or repair, unplug the
compressor and bleed off all air
pressure.
ALL SERVICE AND REPAIR OPERA=
TIONS NOT DESCRIBED iN THiS
MANUAL MUST BE PERFORMED
BY A TRAINED SERVICE TECHNI-
CIAN.
Before servicing:
•Unplug or disconnect electrical
supply to the air compressor.
• Bleed 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 Tank" in the
Maintenance section.
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 ori-
entation 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 the valve
disc in the closed position; if not
moving freely the check valve
needs to be cleaned or replaced.
position
nothing is
visible.
in closed position
disc is visible.
2.
3. Unplug unit.
Using an adjustable wrench,
loosen outlet tube nut at air tank
and pump. Carefully move outlet
tube away from check valve.
7. Clean or replace the check valve.
A solvent, such as paint or var-
nish 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.
D24910 20- ENG