DK2 AC04G User manual

AC04G
TWIN CYLINDER 1 HP 4GALLON OILFREE
SILENT AIR COMPRESSOR
USER MANUAL
CUSTOMER SERVICE 1 (888) 277-6960 | WWW.DK2.COM
DK2 USA WEST
3311 MEADE AVENUE STE
E DOCK 13, LAS VEGAS, NEVADA
89102 USA
DK2 USA EAST
3750 SOUTH AVENUE
NORTH UNIT, TOLEDO, OHIO
43615 USA
DK2 CORPORATE HEAD OFFICE
5330 MAINWAY
BURLINGTON, ONTARIO
L7L6A4 CANADA

2 | AC04G(X) man.
WARRANTY
PLEASE DO NOT RETURN TO THE STORE
YOU HAVE A 1 YEAR WARRANTY AND DK2 WILL REPLACE A DEFECTIVE PART FOR FREE. CALL US AT
1 (888) 277-6960 FOR FAST WARRANTY PARTS AND QUESTIONS.
WHAT IS COVERED – 1 YEAR LIMITED WARRANTY INCLUDED
DK2 warrants to the original purchaser that product will be free and clear of manufacturing defects in workmanship
and materials under normal use and service for a period of one (1) year from the date of the original purchase. If
within one (1) year from the original date of purchase this product fails due to defect in material or workmanship,
DK2 will repair, replace, or supply any covered defective part at our option. DK2 is 1-year parts only warranty no
labor.
Upon expiry of one (1) year, DK2 will have no further liability related to the product. DK2 does not authorize any
party, including its authorized distributors or dealers, to oer any other warranty on behalf of DK2.
SERIAL NUMBERS MUST BE REGISTERED ONLINE AT WWW.DK2.COM, WARRANTY NON-TRANSFERABLE.
DK2 – 1-year parts only, no labor.
THIS WARRANTY DOES NOT COVER OR APPLY TO:
(a) Damage to the product due to misuse, mishandling and abuse
(b) Improper installation, maintenance and storage
(c) Expendable parts such as nuts and bolts, pins and springs, wiring and switch components, hydraulic hoses and
fittings, cutting teeth, cutting chains, cutting blades, throttles, belts and tires
(d) Normal wear and tear
(e) Consequential damage & incidental damages such as damage to persons or property
PROCEDURE FOR WARRANTY
Within the one (1) year warranty period, the purchaser of the product can CALL 1 (888) 277-6960 or contact us on
www.DK2.com. Notify us of the claimed defect and provide proof of original purchase. At this time the validity of the
claim will be determined, and if approved replacement parts will be issued. No returned product will be accepted
under warranty unless accompanied by an RGA# issued by DK2.
DAMAGED FREIGHT
Damage to your product caused by freight mishandling is NOT covered under warranty. If your freight arrives
damaged, REFUSE it. Inspect your product when it arrives, otherwise if you accept it, you will be responsible for
filing any freight claims with the delivery company. DK2 warranty excludes damage to product.
RESOLUTION FOR A DEFECTIVE PRODUCT.
Call us at 1 (888) 277-6960 between 8am-4pm Monday to Friday EST.
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TABLE OF CONTENTS
WARRANTY..........................................................................2
TABLE OF CONTENTS ................................................................3
TECHNICAL SPECIFICATIONS..........................................................4
SECTION I • SAFETY ..............................................................5
SAFETY CONVENTIONS ..............................................................6
BEFORE OPERATION .................................................................6
DESCRIPTION........................................................................6
SAFETY DECALS .....................................................................7
UNPACKING .........................................................................8
GENERAL SAFETY INFORMATION ......................................................8
SECTION II • INSTALLATION....................................................... 11
LOCATION..........................................................................12
ELECTRICAL INSTALLATION ..........................................................12
GROUNDING INSTRUCTIONS.........................................................12
EXTENSION CORDS .................................................................13
SECTION III • OPERATION.........................................................14
COMPONENTS......................................................................15
LUBRICATION .......................................................................15
BREAKIN PROCEDURE ..............................................................16
SAFETY VALVE...................................................................... 17
REGULATOR KNOB .................................................................. 17
TANK PRESSURE GAUGE............................................................. 17
SECTION IV • MAINTENANCE .....................................................18
THERMAL OVERLOAD PROTECTOR ...................................................19
STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MAINTENANCE PROCEDURE SCHEDULE ..............................................20
TROUBLESHOOTING ................................................................20
SECTION V • PARTS & SCHEMATICS ...............................................22
PARTS LIST .........................................................................23
SCHEMATICS .......................................................................24
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TECHNICAL SPECIFICATIONS
POWER 550W/0.75 HP / 750W/1.0 HP
VOLTAGE 110V / 120V
FREQUENCY 60Hz
SPEED 1700RPM
DISPLACEMENT 3.8CFM / 4.0CFM
MAX PRESSURE 125PSI
DECIBELS 67dB
DIMENSIONS 17.4” (L) x 15.6” (W) x 20.8” (H)
44.2cm (L) x 39.5cm (W) x 52.8cm (H)
WEIGHT 54lb (24.5kg)
SHIPPING DIMENSIONS 18.7” (L) x 16.5” (W) x 22.4” (H)
47.5cm (L) x 42cm (W) x 57cm (H)
SHIPPING WEIGHT 57.3lb (26kg)
WARRANTY 1-year limited
ENGLISH

SECTION I • SAFETY

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SAFETY CONVENTIONS
This manual contains information that is very important to know and understand. This information
is provided for safety and to prevent equipment problems. To help recognize this information,
observe the following symbols.
DANGER! This indicates a hazardous situation, which, if not avoided, will result in death or
serious injury.
WARNING! This indicates a hazardous situation, which, if not avoided, could result in death
or serious injury.
CAUTION! This indicates a hazardous situation, which, if not avoided, may cause minor or
moderate injury.
NOTICE! This indicates important information, which, if not avoided, may cause damage
to equipment.
ADDITIONAL INFORMATION AND POTENTIAL CHANGES
We reserve the right to discontinue, change, and improve our products at any time without notice
or obligation to the purchaser. The descriptions and specifications contained in this manual were
in eect at printing. Equipment described within this manual may be optional. Some illustrations
may not be applicable to your equipment.
BEFORE OPERATION
WARNING! Read carefully and understand all assembly and operation
instructions before operating this product. Failure to follow the safety
rules and other basic safety precautions may result in serious personal
injury. Please save these instructions. Read carefully before attempting
to assemble, install, operate or maintain this product. Protect yourself
and others by observing all safety information. Failure to comply with
instructions could result in personal injury and/or property damage. Retain
instructions for future reference.
DESCRIPTION
Oil-free air compressors are designed for “do-it-yourselfers” with a variety of home and automotive
jobs. These compressors power spray guns, impact wrenches and other tools. These units operate
without oil. Compressed air from this unit will contain moisture. Install a water filter or air dryer if
application requires dry air.
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SAFETY DECALS
Make sure all safety warning decals are attached and in readable condition.
AIR COMPRESSOR
COMPRESSEUR À AIR
Model/Modèle : AC04G
Voltage & Current / Tension et courrant
120V ~ 60Hz 7 A
1 HP / 1 CV
4 gal (15.2 L)
1700 rpm / tr/min
125 psi / lb/po2
To reduce the risk of injury, user
must read and understand
instruction manual.
Afin de reduire la risque de
blessures, l’utilisateur doit lire et
bien comprendre le mode d’emploi.
Power / Puissance
Tank / Réservoir
Serial No. / No. de série
Made in China / Fabriqué en Chine
No-load speed / Vitesse sans charge
Max air pressure / Pression d’air max
3043653
WARNING
AVERTISSEMENT
POWER SWITCH
INTERRUPTEUR
Auto/On
Auto/En Marche
O
Hors tension
ACPSL 1709
WARNING AVERTISSEMENT
CALIFORNIA PROPOSITION 65
This product contains chemicals known to the state of
California to cause cancer and birth defects or other
reproductive harm.
PROPOSITION 65 DE CALIFORNIE
Ce produit contient des produits chimiques reconnus
par l’État de Californie pour causer des cancers et des
anomalies congénitales ou d’autre dommages à la
réproduction.
WARNING
AVERTISSEMENT
CALIFORNIA PROPOSITION 65
PROPOSITION 65 DE CALIFORNIE
This product contains chemicals known to
the state of California to cause cancer and
birth defects or other reproductive harm.
Ce produit contient des produits
chimiques reconnus par l’État de
Californie pour causer des cancers et des
anomalies congénitales ou d’autre
dommages à la réproduction.
CAUTION
MISE EN GARDE
Drain the moisture from the tank
every week. Prevent tank
corrosion.
Drainer l’eau et
l’humidité du
réservoir pour
prévenir la corrosion.
ACTDL 1709
WARNING
AVERTISSEMENT
RISK OF BURSTING
Do not adjust factory settings
RISK OF ELECTRIC SHOCK
Do not remove cover
RISQUE D’ÉCLATEMENT
Ne pas changer les réglages d’usine
RISQUE DE CHOC ÉLECTRIQUE
Ne retirez pas le couvercle
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UNPACKING
After unpacking the unit, inspect carefully for any damage that may have occurred during transit.
Make sure to tighten fittings, bolts, etc., before putting the unit into service.
WARNING! Do not operate this product if damaged during shipping, handling, or use.
Damage may result in bursting and cause injury or property damage.
GENERAL SAFETY INFORMATION
Since the air compressor and other components (material pump, spray guns, filters, lubricators,
hoses, etc.) used, make up a high-pressure pumping system, the following safety precautions
must be observed at all times:
1. Follow all local electrical and safety codes as well as in the US, National Electrical
Codes (NEC) and Occupational Safety and Health Act (OSHA).
2. Only persons well acquainted with these rules of safe operation should be allowed to
use this product.
3. Keep visitors away and NEVER allow children in the work area.
WARNING! RISK FROM FLYING OBJECTS: Always wear approved
safety glasses with side shields when the air compressor is in use. Turn
o 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.
4. Wear safety glasses and use hearing protection when operating the pump or unit.
5. Do not stand on or use the pump or unit as a handhold.
6. Before each use, inspect compressed air system and electrical components for signs of
damage, deterioration, weakness or leakage. Repair or replace defective items before
using.
7. Check all fasteners at frequent intervals for proper tightness.
DANGER! RISK TO BREATHING: Avoid using the air compressor in
confined areas. Always have adequate space (12”/30cm) on all sides of
the air compressor. Keep children, pets, and others out of the area of
operation. This unit 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. This compressor is not equipped and should not be used “as is” to supply
breathing quality air. For any application of air for human consumption, the air compressor
will need to be fitted with suitable in-line safety and alarm equipment. This additional
equipment is necessary to properly filter and purify the air to meet minimal specifications for
Grade D breathing as described in Compressed Gas Association Commodity Specification
G7.1-1966, OSHA 29 CFR 1910.134, and/or Canadian Standards Associations (CSA).
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WARNING! Motors, electrical equipment and controls can cause electrical
arcs that will ignite a flammable gas or vapor. Never operate or repair in
or near a flammable gas or vapor. Never store flammable liquids or gases
in the vicinity of the compressor.
CAUTION! RISK OF BURNS: Compressor parts may be hot even if the
unit is stopped. 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.
8. Keep fingers away from a running compressor, fast moving and hot parts will cause
injury and/or burns.
9. If the equipment should start to abnormally vibrate, STOP the engine/motor and check
immediately for the cause, vibration is generally a warning of trouble.
10. To reduce fire hazard, keep engine/motor exterior free of oil, solvent, or excessive
grease.
WARNING! Never remove or attempt to adjust safety valve. Keep safety valve free from
paint and other accumulations.
DANGER! RISK OF BURSTING: 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 a leak has been found
or tried to make any modifications to the tank. Never modify the air
compressor’s factory settings which control the tank pressure or any
other function. Welding drilling, or any other modification will weaken the
tank resulting in damage from rupture or explosion. Always replace worn
or damaged tanks.
WARNING! Drain liquid from tank daily.
11. Tanks rust from moisture build-up, which weakens the tank. Make sure to drain tank
regularly and inspect periodically for unsafe conditions such as rust formation and
corrosion.
12. Fast moving air will stir up dust and debris, which may be harmful. Release air slowly
when draining moisture or depressurizing the compressor system.
WARNING! RISK OF EXPLOSION OR FIRE: Never operate the
compressor near combustible materials, gasoline or solvent vapors. If
spraying flammable materials, locate the air compressor at least 50m
away from the spray area. Never operate the air compressor indoors or
in a confined area. Do not spray flammable materials in vicinity of open
flame or near ignition sources including the compressor unit.
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10 | AC04G(X) man.
13. Do not smoke when spraying paint, insecticides, or other flammable
substances.
14. Use a face mask/respirator when spraying and spray in a well ventilated
area to prevent health and fire hazards.
15. Do not direct paint or other sprayed material at the compressor.
Locate compressor as far away from the spraying area as possible to
minimize over-spray accumulation on the compressor
16. When spraying or cleaning with solvents or toxic chemicals, follow the
instructions provided by the chemical manufacturer.
WARNING! RISK OF MOVING PARTS: 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 have 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.
WARNING! RISK OF FALLING: Operation of the air compressor should
always be in a position that is stable. Never use the air compressor on a
rooftop or elevated position that could allow the unit to fall or be tipped
over. Use additional air hose for elevated jobs.
DANGER! RISK OF ELECTRICAL SHOCK: 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.
ENGLISH

SECTION II • INSTALLATION

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LOCATION
It is extremely important to install the compressor in a clean, well-ventilated area where the
surrounding air temperature will not be more than 100˚F.
A minimum clearance of 18 inches between the compressor and a wall is required because objects
could obstruct airflow.
CAUTION! Do not locate the compressor air inlet near steam, paint spray, sandblast areas
or any other source of contamination. This debris will damage the motor.
ELECTRICAL INSTALLATION
WARNING! All wiring and electrical connections should be performed by a qualified
electrician. Installation must be in accordance with local codes and national electric codes.
CAUTION! Never use an extension cord with this product. Use additional air hose instead of
an extension cord to avoid power loss and permanent motor damage; use of an extension
cord voids the warranty.
GROUNDING INSTRUCTIONS
1. This product is for use on a nominal 120 volt
circuit and has a grounding plug that looks
like the plug shown (Fig.1). Make sure the
product is connected to an outlet having
the same configuration as the plug. This
product must be grounded. In the event
of an electrical short circuit, grounding
reduces risk of electrical shock by providing
an escape wire for electric current. This
product is equipped with a cord having a grounding wire with an appropriate grounding
wire with an appropriate grounding plug. Plug must be plugged into an outlet that is
properly installed and grounded in accordance with all local codes and ordinances.
DANGER! Improper use of grounding plug can result in a possible risk of
electrical shock.
DANGER! Do not use a grounding adapter with this product.
2. If repair or replacement of cord or plug is necessary, do not connect grounding wire
to either flat blade terminal. The wire with insulation having an external surface that is
green (with or without yellow stripes) is the grounding wire.
FIGURE 1
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v.220629 | 13
WARNING! Never connect green (or green and yellow) wire to a live terminal.
3. Check with a qualified electrician or serviceman if grounding instructions air not
completely understood, or if in doubt as to whether product is properly grounded.
Do not modify plug provided; if it will not fit outlet, have proper outlet installed by a
qualified electrician.
WARNING!
4. Local electrical wiring codes dier from area to area. Source wiring, plug and protector
must be rated for at least the amperage and voltage indicated on motor nameplate,
and meet all electrical codes for this minimum.
5. Use a slow blow fuse or a circuit breaker.
EXTENSION CORDS
To avoid voltage drop, power loss, and overheating of the motor, use extra air hose instead of an
extension cord. Low voltage can cause damage to the motor.
If an extension cord must be used:
• Use only an approved 3-wire extension cord that has a 3-blade grounding plug and a
3-slot receptacle that will accept the plug on the air compressor.
• Make sure the extension cord is in good condition.
Please see the chart below for the MINIMUM extension cord gauge requirements:
Amp Rating Range (120V)
Total Length of Extension Cord
25ft
(10m)
50ft
(15m)
75ft
(20m)
100ft
(30m)
150ft
(50m)
200ft
(60m)
0 - 5 A 16 16 16 14 12 12
5 - 8 A 16 16 14 12 10
8 - 12 A 14 14 12 10
12 - 15 A 12 12 10 10 NOT RECOMMENDED
15 - 20 A 10 10 10
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SECTION III • OPERATION

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COMPONENTS
PRESSURE SWITCH
Auto/O Switch - In the AUTO position, the compressor shuts o automatically when tank pressure
reaches the maximum preset pressure. In the OFF position, the compressor will not operate. This
switch should be in the OFF position when connecting or disconnecting the power cord from the
electrical outlet or when changing air tools.
REGULATOR
The regulator controls the amount of air pressure released at the hose outlet.
SAFETY VALVE
This valve automatically releases air if the tank pressure exceeds the preset maximum.
DISCHARGE TUBE
This tube carries compressed air from the pump to the check valve. This tube becomes very hot
during use. To avoid the risk of severe burns, never touch the discharge tube.
CHECK VALVE
A one-way valve that allows air to enter the tank, but prevents air in the tank from flowing back
into the compressor pump.
HANDLE
Designed to move the compressor.
WARNING! Never use the handle on wheeled units to lift the unit completely o the ground.
DRAIN PETCOCK
This valve is located on the bottom of the tank. Use this valve to drain moisture from the tank daily
to reduce the risk of corrosion.
Reduce tank pressure below 10PSI, and then drain moisture from tank daily to avoid tank corrosion.
Drain moisture from tank by opening the drain petcock located underneath the tank.
LUBRICATION
This is an oil-free product and DOES NOT require lubrication to operate.
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16 | AC04G(X) man.
BREAK-IN PROCEDURE
CAUTION! Do not attach air chuck or other tool to open end of hose until start-up has been
completed and unit checks okay.
NOTICE! Do not operate the compressor before reading instructions or damage may
result. (Refer to Fig.2 and Fig.3)
1. Turn regulator (Fig.3) fully clockwise
to open airflow.
2. Turn switch (Fig.2) to OFF position
and plug in power cord.
3. Turn switch (Fig.2) to ON position
and run unit for 30 minutes to break
in the pump parts.
4. Turn regulator knob (Fig.3) fully
counter-clockwise. Compressor will
build to maximum preset pressure
and shut o.
5. Turn regulator knob (Fig.3) clockwise
to cause air to bleed o. Compressor
will restart at a preset pressure.
6. Turn regulator knob (Fig.3) counter-
clockwise to shut o the air and turn
switch to o position.
7. Attach chuck or other tool to open
end of hose. Turn the regulator (Fig.3) on. With the switch (Fig.2) in the ON position,
the compressor pumps air into the tank. It shuts o automatically when unit reaches
its maximum preset pressure. In the OFF position, the pressure switch cannot function
and the compressor will not operate. Make sure switch (Fig.2) is in OFF position when
connecting or disconnecting power cord from electrical outlet.
NOTICE! MOISTURE IN COMPRESSED AIR: Moisture in compressed air will form into
droplets as it comes from an air compressor pump. When humidity is high or when a
compressor is in continuous use for an extended period of time, this moisture will collect
in the tank. When using a paint spray or sandblast gun, this water will be carried from the
tank through the hose, and out of the gun as droplets mixed with the spray material. This
condensation will cause water spots in a paint job, especially when spraying other than
water based paints. If sandblasting, it will cause the sand to case and clog the gun rendering
it ineective. A filter in the air line (MP3105), located as near to the gun as possible, will help
eliminate this moisture.
FIGURE 2: PRESSURE SWITCH / INTERRUPTEUR DE PRESSION
SWITCH HANDLE
POIGNÉE DE L’INTERRUPTEUR
OFF
ON
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v.220629 | 17
SAFETY VALVE
WARNING! DO NOT REMOVE OR ATTEMPT TO ADJUST THE SAFETY VALVE: This valve
should be checked under pressure occasionally by pulling the ring by hand. If air leaks
after ring has been released, or valve is stuck and cannot be actuated by ring, it MUST be
replaced.
REGULATOR KNOB
(See Fig.3)
1. This knob controls air pressure to
an air-operated tool or paint spray
gun.
2. Turn clockwise to increase air
pressure at outlet. When desired
pressure is reached, lock with nuts.
3. To lower air pressure at outlet, turn
counter-clockwise.
4. Turn fully counter-clockwise to shut
o flow of air completely then push
knob down.
TANK PRESSURE GAUGE
This gauge shows pressure in tank indicating compressor is building pressure properly.
FIGURE 3: PRESSURE REGULATING VALVE / SOUPAPE DE RÉGULATION DE PRESSION
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SECTION IV • MAINTENANCE

v.220629 | 19
WARNING! Disconnect power source then release all pressure from
the system before attempting to install, service, relocate or perform any
maintenance. Check compressor often for any visible problems and
follow maintenance procedures each time compressor is used.
1. Pull ring on safety valve and allow it to snap back to normal position.
WARNING! Safety valve must be replaced if it cannot be actuated or it leaks air after ring
is released.
2. Turn compressor o and release pressure from system. Drain moisture from tank by
opening drain cock underneath tank.
3. Clean dust and dirt from motor, tank, and airlines and pump cooling fins while compressor
is still OFF.
NOTICE! Locate the unit as far from spraying area as possible, as hose will limit over-spray
from clogging the filter.
THERMAL OVERLOAD PROTECTOR
CAUTION! This compressor is equipped with an automatic reset thermal overload protector,
which will shut o motor if it becomes overheated. If thermal overload protector shuts
motor OFF frequently, look for the following causes.
1. Low voltage
2. Clogged air filter
3. Lack of proper ventilation
CAUTION! If the thermal overload protector is actuated, the motor must be allowed to cool
down before start-up is possible. The motor will automatically restart without warning if left
plugged into electrical outlet and unit is turned on.
STORAGE
1. When not in use, store hose and compressor in a cool, dry place.
2. Drain tank of moisture.
3. Disconnect hose and hang open ends down to allow any moisture to drain.
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20 | AC04G(X) man.
MAINTENANCE PROCEDURE SCHEDULE
WARNING! Qualified service personnel should perform any service procedure not covered
in the maintenance schedule below.
PROCEDURE 1 2 3 LEGEND
Check tank safety valve BEFORE EACH USE OR DAILY 1
Overall unit visual check AFTER FIRST 10 HOURS 2
Check air filter (more frequently in dusty or humid
environments)
EVERY 100 HOURS 3
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Compressor will not
run.
1. No electrical power
2. Blown fuse
3. Breaker open
4. Thermal overload open
5. Faulty pressure switch
1. Plugged in? Check fuse/breaker or motor overload
2. Replace blown fuse
3. Reset, determine cause of problem
4. Motor will restart when cool
5. Replace
Motor hums but
cannot run or runs
slowly.
1. Defective check valve or
unloaded
2. Poor contacts, line
voltage low
3. Shorted or open motor
winding
1. Replace or repair
2. Check connections, eliminate extension cork if used,
check circuit with voltmeter
3. Replace motor
DANGER! Do not disassemble check valve with
air in tank; bleed tank.
Fuses blow/circuit
breaker trips
repeatedly.
CAUTION!
Never use
an extension
cord with
this product.
1. Incorrect size fuse,
circuit overload
2. Defective check valve or
unloaded
1. Check for proper fuse, use time-delay fuse.
Disconnect other electrical appliances from circuit or
operate compressor on its own branch circuit
2. Replace or repair
DANGER! Do not disassemble check valve with
air in tank; bleed tank.
ENGLISH
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