Craftsman 921.153101 User manual

Owner's Manual
I CRAFTSMAN®I
AIR COMPRESSOR
3-gallon
1HP
Oil Lubricated
Model No. 921.153101
AWARNING
FILL WITH OIL BEFORE USE.
CAUTION:
Before using
this product,
read this manual and follow
all its Safety Rules and
Operating Instructions.
•Safety Instructions
•Installation &Operation
•Maintenance &Storage
•Troubleshooting Guide
•Parts
List
•Espanol, p. 10
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
www.sears.com/craftsman
03/24/2006
Part No. E101139

TABLE OF CONTENTS
Page
Warranty....................................................................................................... see below
Safety Instructions .
Important Safety Instructions &Guidelines
..
Specifications......................................................................................................... 2
Glossary 2
Duty Cycle 2
Parts &Features................................................................................................... 3
Installation &Assembly 4
Operating Procedures 5
Maintenance.......................................................................................................... 6
Storage 6
Troubleshooting Guide 7
Parts List. :........................................................................ 8
Espanol....................................................................................................................
10
Service Number.......................................................................................... back cover
ONE YEAR FULL WARRANTY ON CRAFTSMAN AIR COMPRESSOR
If this Craftsman Air Compressor fails due to manufacturer's defects in material or workmanship
within one year of the date of purchase, RETURN IT TO THE NEAREST SEARS STORE OR
SERVICE CENTER
IN THE UNITED STATES and it will be replaced or repaired (at our option),
free of charge.
If this Air Compressor
is used for commercial or rental purposes, this warranty applies for only 90
days from the date of purchase. This warranty gives you specific legal rights and you may also
have other rights which vary from state to state.
Sears, Roebuck and Co., Dept. 817WA,
Hoffman Estates, IL 60179

Safety Instructions
The information listed below should be read and
understood by the operator. This information
is given to
protect the user while operating and storing the air
compressor.
We utilize the symbols below to allow the
reader to recognize important information about their
safety.
~
~
Indicates an imminently hazardous situation which, if Indicates apotentially hazardous situation which, if not
not avoided, will result
in death or serious injury. avoided, may result in minor or moderate injury.
~
mmmm
Indicates apotentially hazardous situation which, if not When used without the safety alert symbol indicates a
avoided, could result
in death or serious injury potentially hazardous situation which, if not avoided,
may result
in property damage.
Important Safety Instructions and Guidelines
•Save all instructions
~
Improper operation or maintenance of this product could result in serious injury and/or property damage. Read and
understand all of the warnings and safety instructions provided before using this equipment.
Risk of Moving Parts
~
Risk of Burns
Risk of Falling
fiJ
Risk from
Flying Objects
~
The air compressor should be operated on adedicated 15 amp circuit. If the circuit
does not have 15 free amps available, alarger circuit must
be used. Always use more
air hose before utilizing extension cords. All extension cords used must
be 12 gauge
with amaximum length of 25
ft. The circuit fuse type must be atime delay. Low volt-
age could cause damage to the motor.
If the air compressor is in operation, all guards and covers should be attached or
installed correctly.
If any guard or cover has been damaged, do not operate the
equipment until the proper personnel has correctly repaired the equipment. The power
cord should
be free of any moving parts, twisting and/or crimping while in use and
while
in storage.
There are surfaces
on your air compressor that while in operation and thereafter can
cause serious burns if touched. The equipment should
be allowed time to cool before
any maintenance
is attempted. Items such as the compressor pump and the outlet
tube are normally hot during and after operation.
Operation of the air compressor should always
be in aposition that is stable. Never
use the air compressor
on arooftop or elevated position that could allow the unit to
fall or
be tipped over. Use additional air hose for elevated jobs.
Always wear ANSI Z87.1 approved safety glasses with side shields when the air
compressor
is in use. Turn off the air compressor and drain the air tank before
performing any type of maintenance or disassembly of the hoses or fittings. Never
point any nozzle or sprayer toward any part of the body or at other people or animals.

Important Safety Instructions &Guidelines
Risk to Breathing
Risk of
Electrical Shock
~
Risk of
Explosion or Fire
Risk of Bursting
~
Avoid using the air compressor in confined areas. Always have adequate space
(12 inches) on all sides of the air compressor. Also keep children, pets, and others
out of the area of operation. This air compressor does not provide breathable air for
anyone or any auxiliary breathing device. Spraying material will always need to
be
in another area away from the air compressor to not allow intake air to damage the air
compressor filter.
Never utilize the air compressor
in the rain or wet conditions. Any electrical issues
or repairs should be performed by authorized personnel such as an electrician and
should comply with all national and local electrical codes. The air compressor should
also have the proper three prong grounding plug, correct voltage, and adequate fuse
protection.
Never operate the compressor near combustible materials, gasoline or solvent vapors.
If spraying flammable materials, locate the air compressor at least 20 feet away from
the spray area. Never operate the air compressor indoors or
in aconfined area.
Always drain the air compressor tank daily or after each use. If the tank develops a
leak, then replace the air compressor. Never use the air compressor after aleak has
been found or try to make any modifications to the tank. Never modify the air compres-
sor's factory settings which control the tank pressure or any other function.
Specifications
Pump Oil-lube direct drive
Motor Induction 1HP
Bore 1.65
11
Stroke. ......................1.26
11
Voltage Single Phase 120 VAC
Glossary
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per minute; aunit of measure
for air delivery.
PSIG: Pounds per square inch gauge; aunit of measure
for pressure.
ASME: American Society of Mechanical Engineers.
California Code: Unit may comply with California Code
462
(I) (2)/ (M) (2).
Cut-In Pressure: The air compressor will automatically
start to refill the tank when the pressure drops
below the prescribed minimum.
Minimum Circuit Requirement 15 Amps
Air Tank Capacity 3Gallons
Cut-in Pressure 95 PSI
Cut-out Pressure 125 PSI
SCFM @90 PSI. 2.4
Cut-Out Pressure: The point at which the motor stops
when the tank has reached maximum air
pressure.
Code Certification: Products that bear one or more of
the following marks: UL, CUL, ETL, CSA, have
been evaluated by OSHA-certified independent
safety laboratories and meet the applicable
Underwriters Laboratories Standards for Safety.
Duty Cycle
This is a50% duty cycle air compressor. Do not run the air compressor more than 30 minutes of one hour. Doing so
could damage the air compressor.
2

Parts &Features
See figures below for reference.
Air Intake Filter
Provides clean air to the pump and must always be kept free of debris. Check
on adaily basis or before each use.
Tank Safety Valve
Used to allow excess tank pressure to
escape into the atmosphere. This valve
should only open when the tank pressure
is above the maximum rated pressure.
Regulator
The air pressure coming from the air tank
is
controlled by the regulator. To increase the
pressure, turn the knob clockwise, and to
decrease the pressure, turn the knob
counterclockwise.
Pressure Relief Valve
The pressure relief valve, located
on the
side of the pressure switch, is designed to
automatically release compressed air when
the air compressor reaches cut-out pressure.
The released air should only escape
momentarily, and the valve should then close.
Pressure Switch
This controls the power to the motor and also the
cut-in/cut-out pressure settings. This switch serves
as the Auto-On/Off ositions for the unit.
Tank Pressure Gauge
Indicates the reserve air pressure
in the tank.
Regulator Gauge
Indicates the outgoing air pressure to the tool and
is controlled
by the regulator.
Quick Connect
Offers aquick release feature for attaching and removing the air hose.
Tank Drain Valve
Used to drain condensation from the air tank. Located at bottom of tank.
Pressure
Relief Tube
Oil Fill Cap
Outlet Tube
Oil Sight Gauge
Check Valve
When the pump
is not in operation, the valve closes to retain air pressure inside the tank. An internal component.
3

Installation & Assembly
~
r'~
Plug ii~.1
c~y! ~ IGrounded
-:::=:::~~I (~ Outlet
I L~
Grounding Pin ~'~"J
Grounding Instructions
This product should be grounded. In the event of an electrical
short circuit, grounding reduces the risk of electric shock by
providing
an escape wire for the electric current. This product is
equipped with acord having agrounding wire with an
appropriate grounding plug. (See the figure below.) The plug
must be plugged into an outlet that is properly installed and
grounded
in accordance with all local codes and ordinances.
Check with aqualified electrician or service
personnel if these
instructions are not
completely understood
or if
in doubt as to
whether the tool is
properly grounded.
Location of the Air Compressor
The air compressor should always be located
in aclean, dry,
and well ventilated environment. The unit should have at
minimum, 12 inches of space on each side. The air filter intake
should be free of any debris or obstructions. Check the air filter
on adaily basis to be sure it is clean and in working order.
Improper installation of the grounding plug will result
in arisk
of electric shock. If repair or replacement of the cord or plug
is
necessary, do not connect the grounding wire to either flat blade
terminal. The wire with insulation having
an outer surface that is
green with or without yellow stripes is the grounding wire. Check
with aqualified electrician or serviceman if the grounding
instructions are not completely understood, or if in doubt as to
whether the product is properly grounded. Do not modify the
plug provided; if it will not fit the outlet, have the proper outlet
installed by aqualified electrician.
This product is for use
on acircuit having anominal rating of
120 volts and
is factory-equipped with aspecific electric cord
and plug to permit connection
to aproper electric circuit. Make
sure that the product is connected to an outlet having the same
configuraUon as the plug. No adapter should be used with this
product. If the product must be reconnected for use on a
different type of electric circuit, qualified service personnel
should make the reconnection.
Extension Cords
Use only a3-wire extension cord that has a3-blade grounding
plug, and a3-slot receptacle that will accept the plug
on the
product. Make sure your extension cord is in good condition.
When using an extension cord, be sure to use one heavy
enough to carry the current your product will draw. Cords must
not exceed 25 feet and No. 12 AWG size must be used.
An
undersized cord will cause adrop in line voltage resulting in loss
of power and overheating.
Break
In Procedures
No break in procedure is required by the user. This product is
factory tested to ensure proper operation and performance.
To Install the Air Intake Filter
Remove the plastic plug from the
compressor head. Remove the air intake
filter from the poly bag and thread it onto the
head of the compressor as shown.
The air compressor should be turned off and unplugged from
the power source before any maintenance
is performed as well
as the air bled from the tank and the unit allowed time to cool.
Personal injuries could occur from moving parts, electrical
sources, compressed air or hot surfaces. The regulator
assembly must be attached before use. Failure to assemble
correctly could result
in leaks and possible injury. If unsure of
assembly instructions or you experience difficulty
in the assembly
please call your local service department for further instruction.
Quick Connect Assembly
1. Before assembly, be sure that the ~I w
a
Quick Connect (Q.C.) threads have a ~
sealant applied from the factory to prevent (, f\ :t==
leaks around the threa,ds. If no sealant is \ <\,~
present, wrap the threaded portion with ~ ~ ~~
Teflon tape. ~
2. Remove the regulator's plastic plug. Attach \
the Q.C. assembly to the air compressor by aligning the Q.C.
threads to the regulator
on the manifold. Be certain to align
the threads before tightening to prevent thread damage.
3. After hand tightening, the assembly should be turned clock
wise 1to 1.5 revolutions with a13/16ths size wrench.
To prevent damage and leaks, do not over-tighten.
Lubrication and Oil
Remove the oil fill cap by turning it
counter-clockwise by hand. Fill the
compressor pump with
an air compressor oil
such as SAE-30 non-detergent (API CG/CD
Heavy Duty) oil at slow intervals until the oil
reaches the center of the red circle
in the
sight glass (see figure above). Use SAE-10
during extreme winter conditions.
Do not attempt to start the air compressor
without first adding oil to the crankcase. Serious damage can
result unless filled with
oil The pump is shipped without oil from
the factory. Only use non-detergent oils since multi-viscosity
motor oils leave carbon deposits on pump components, thus
reducing performance and compressor life.
~
Drain the tank to release all tank air
pressure before removing the oil fill cap.
Be
sure the air vent in the oil fill cap (see figure
to the right)
is free from debris. If air vent
is blocked, pressure can build in crankcase
causing damage to the compressor and pos-
sible personal injury.
4

Operating Procedures
Daily Start-Up Procedures
CD Set the Auto-On/Off lever to the Off position.
@Check the air compressor visually for any damage
or obstruction.
®Close the drain valve.
@Check the oil level of the pump.
®Connect the air hose to the quick connect socket on
the regulator assembly by inserting the quick connect
plug
on the air hose into the quick connect socket. The
quick connect socket collar will snap forward and lock
the plug into place providing an air tight seal between
the socket and plug. To release the air hose, push the
collar back
on the quick connect socket.
®Plug the power cord into the proper receptacle.
(J) Turn the Auto-On/Off lever to the On-Auto position,
and the compressor will start and build air pressure
in
the tank to cut-out pressure and then shut off
automatically.
®Adjust the regulator to a PSI setting that is needed for
your application, and
be sure it is within the safety
standards required to perform the task.
If using a
pneumatic tool, the manufacturer should have
recommendations
in the manual for that particular
tool
on operating PSI settings.
Note: The air compressor
is now ready for use. The
following inflation and cleaning accessories packaged
with this unit should only
be operated at maximum
pressure of 20-30 PSI: blow gun, tapered nozzle,
inflation needles, blow gun adapter.
Daily Shut-Down Procedures
1. Set the Auto-On/Off lever to the Off position.
2. Unplug the power cord from the receptacle.
3. Set the outlet pressure to zero on the regulator.
4. Remove any air tools or accessories. When draining
the tank, always use ear and eye protection. Drain the
tank
in asuitable location; condensation will be present
in most cases of draining.
5. Open the drain valve allowing air to bleed from the
tank. After all of the air has bled from the tank, close
the drain valve to prevent debris buildup
in the valve.
5
~
When draining the tank, always use ear and eye protection.
Drain the tank
in asuitable location; condensation will be
present in most cases of draining.
Water that remains
in the tank during storage will corrode
and weaken the air tank which could cause the tank to
rupture. To avoid serious injury,
be sure to drain the tank
after each use or daily.

Maintenance
NOTE: Any service procedure not covered in the maintenance schedule below should be performed by qualified service
personnel.
Items to Check/Change Before each After first Every
use or daily
10 hours 100 hours
Check Tank Safety Valve X
Overall Unit Visual Check X
Check Oil Level X
Change Oil X X
Check Air Filter (more frequently in dusty or humid environments) X
Drain Tank (after each use or daily) X
~
To ensure efficient operation and longer life of the air
compressor unit, aroutine maintenance schedule should
be followed. The following schedule is geared toward a
consumer whose compressor
is used in anormal working
environment
on adaily 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 used
in an extremely dirty and/or hostile
environment will require agreater frequency of all
maintenance checks.
Oil Changing
For changing the pump oil, be sure to do the following:
1. Turn the unit off and unplug the power cord from the
receptacle.
2. Allow the compressor time to cool if it has been in
operation.
3. Open the drain valve to bleed all air from the tank.
4. Close the drain valve.
5. Remove the oil fill cap on the pump.
6. Remove the sight glass with abox end wrench or
socket. Drain the oil into asuitable container and
dispose of properly. The compressor may need to
be
tipped slightly towards the drain hole to allow all of the
oil
to drain.
Storage
For storing the air compressor, be sure to do the following:
1. Turn the unit off and unplug the power cord from the
receptacle.
2. Remove all air hoses, accessories, and air tools from
the air compressor.
3. Perform the daily maintenance schedule.
6
~
The air compressor should be turned off and unplugged
from the power source before any maintenance
is
performed as well as the air bled from the tank and the
unit allowed time to cool. Personal injuries could occur
from moving parts, electrical sources, compressed air or
hot surfaces.
7. Reattach the sight glass. Note: Torque the sight glass
10-12 inch
Ibs. when re-assembling. Be sure the gasket
is between the sight glass and the pump crankcase.
8. Refill the compressor pump with an air compressor oil
such as SAE-30 non-detergent (API CG/CD Heavy
Duty)
oil at slow intervals until the oil reaches the center
of the red circle in the sight glass. Use aSAE-10 during
extreme winter conditions.
4. Open the drain valve to bleed all air from the tank.
5. Close the drain valve.
6. Store the air compressor in aclean and dry location.

Troubleshooting Guide
_The air compressor should be turned off and unplugged from the power source before any
~ maintenance is performed as well as the air bled from the tank and the unit allowed time to cool.
Personal injuries could occur from moving parts, electrical sources, compressed air, or hot surfaces.
PROBLEM
Air leaks at the check valve
or at the pressure relief valve.
Air leaks between head and
cylinder.
Air leak from safety valve.
Pressure reading
on the
regulated pressure gauge
drops when
an accessory is
used.
Excessive tank pressure.
Motor will not start.
Excessive moisture
in the
discharge
air.
Air leaks from the tank body
or tank welds.
POSSIBLE CORRECTION
Adefective check valve results in aconstant air leak at the pressure relief valve
when there
is pressure in the tank and the compressor is shut off. Drain the tank,
then remove and clean or replace the check valve.
Be sure of proper torque on head bolts. If leak remains, contact aservice technician.
Operate the safety valve manually by pulling
on the ring. If the valve continues to
leak when
in the closed position, it should be replaced.
If there is an excessive amount of pressure drop when the accessory
is used,
replace the regulator.
NOTE:
Adjust the regulated pressure under flow conditions (while accessory is being used).
It is normal for the gauge to show minimal pressure loss during initial use of the
tool.
Move the Auto-On/Off lever to the Off position.
If the unit doesn't shut off, unplug it
from the power source and contact aservice technician.
Make sure power cord
is plugged in and the switch is on. Inspect for the proper size
fuse
in your circuit box. If the fuse was tripped, reset it and restart the unit. If
repeated tripping occurs, replace the check valve or contact aservice technician.
Remove the water
in the tank by draining after each use. High humidity
environments will cause excessive condensation. Utilize water filters
on your air
line.
NOTE:
Water condensation is not caused by compressor malfunction. Be sure the
compressor's air output is greater than your tool's air consumption rate.
Never drill into, weld or otherwise modify the air tank or it will weaken. The tank
can
rupture or explode. Compressor cannot be repaired. Discontinue use of the air
compressor.
7

Craftsman Air Compressor Model 921.153101
Parts List
23--
55---
8
37
~57
"\
\ ~ \
~ ~64 "
\\
52 \
56 \\ /53
51\ \

Craftsman Air Compressor Model 921.153101
Parts List
Reference Kit Part
Description Quantity
Reference Kit Part
Description
Quantity
Number Number Number
Number Number Number
E100434
Intake Filter Housing, 41 Ferrule, Compression, 1/4 inch
2
1/2 NPT
42 E100957 Pressure Switch
1
2
E100435
Filter Element 1
43 E100594 Strain Relief
2
3
Screw, Socket Head,
4
44
E100205
Pressure Gauge, 2" 200PSI
1
M6 x 1.0 x 30mm
45 E100093 Pressure Gauge, 1.5" 200PSI
1
4
Lock Washer, 6mm
8
46 E100094 Safety Valve
1
5
E100227
Cylinder Head 1
47 E100059 Regulator
1
6
E100809 Exhaust Elbow 1
48 E100307
Coupler, Quick connect 1
72
Gasket, Head 1
49 E100595 Nipple,1/4"NPTx25mm
1
8
E100228 Valve Plate
2
50
E100853
Nipple,1/4"NPTx35mm
1
9
E100229
Valve Reed
2
51
E100958 Outlet Tube
1
10 2 Gasket, Valve Plate
1
52 Nut, Compression, 3/8 inch
2
11
2 Gasket, Cylinder Upper
1
53
Ferrule, Compression, 3/8 inch
2
12
Cylinder, ID42mm x H65mm
1
54 E100097 Grip, Handle
1
13
Screw, Socket Head,
5
55
Tank
1
M6 x 1.0 x 20mm
56
E100098
Drain Valve, 1/4"NPT 1
14
2
Gasket, Cylinder Lower
1
57
E100898 Check Valve
1
15
3
Ring, Compression
2
58
6
Flat Washer, 8mm
12
16
3
Ring, Scraper
1
59
6
Isolator, Rubber
4
17
3
Piston
1
60
6
Screw, Hex Head,
4
18
3 Piston Pin
1
M8 x 1.25 x 25mm
19
3
Snap Ring, 12mm
2
61
6
Washer, Lock, 8mm
8
20
3
Rod Connecting
1
62
E100101 Power Cord 14/3 X 6'
1
21
3 Nut, M6x1.0
1
63
Screw, Socket Head,
4
22
3
Eccentric
1
M8 x 1.25 x 16mm
23 4 Oil Fill Cap
1
64
E101193
Plug, Plastic, for Handle
24
4o Ring, OD17mm x 2mm
1
Not Shown
E100110 Label, Drain Tank Warning 1
25 Cover, Crankcase
1
Not Shown E100730
Label, Specification HP, Tank size 1
26 E101000 Screw, Hex Flange Head,
4
Not Shown
E100859 Label, Warning Bilingual Tank
1
M5 x 0.8 x 15mm
Not Shown E101176 Manual, Operators/Parts
1
27
5
Seal, Oil Sight Gauge
1
28
5 Gauge, Oil Sight
1
Note: Any part/kit number field without a number is not available.
29 2
Baffle, Rubber
1
Descriptions are provided for reference only. The Kit # column represents
30
6 Nut, M8x1.25 10
that the part being offered is available in a kit. One of each part per kit will
31
Washer, Tooth Lock, 5/16 inch
2
be offered.
32
Screw, Round Head, Phillips, 4
M3 x 0.5 x 6mm
Kit number and parts that are included are as follows:
33 Washer, Lock, 3mm 4
34 E100248
Capacitor, Starting (200~F) 1
Kit No. Part No.
Description
Reference No.
35
E100247
Capacitor, Running (40~F)
11
E100794
Intake Filter Kit
1,2
36
Motor
12
E100959
Gasket Kit 7, 10-11, 14, 29
37
E100955 Shroud
13
E100251 Piston Kit 15-22
38 E100854
Screw, Hex Flange Head,
64
E100087 Oil Fill Cap w/O-ring
23-24
M5 x 0.8 x 10mm
5
E100088 Oil Sight Gauge w/O-ring
27-28
39
E100956 Pressure Relief Tube
16
E100102 Isolator Kit 30,55-57
40
Nut, Compression, 1/4 inch
2
9

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