Makita MAC1200 User manual

.
OWNERS MANUAL FOR
Permanently Lubricated Air Compressor
MODEL NO.
MAC1 200
SPECIFICATION CHART
NOTE: IMPORTANT:
For identification of Parts, see Page 11 in this
Manual. Carefully Before Operating.
Read the Safety Guidelines and
All Instructions
Minimum Circuit Requirement
15 AMPS
+A circuitbreaker ispreferred.Useonly a fuseor circuit breakerthat isthesame ratingasthebranch
circuit the air compressor is operated on.
If the air compressor is connected to a circuit protected
by fuses, use time delay fuses.
I
Model No.
Horsepower
Displacement CFM
SCFM
G2 40 psig
SCFM
G2 9Opsig
Cut-In
cut-out
Bore
Stroke
Voltage-SinglePhase
+ Fuse Type
Amperage
at Max. Pressure
Tank Size
U.L.
& CUL Listed
MAC? 200 ,
;c*
2
11.9
8.3
6.1
100 PSI
125
PSI
2 38"
1.35"
120
15amps
4 Gallon
"Fusetron"TypeT
k
~
WMAC12QQA Rev. 1/14/97

TABLE OF CONTENTS
This manual contains informa-
tion that is important for you to
know and understand
. This infor-
mationrelates
to protecting YOUR
SAFETY andPREVENTINGEQUIP-
MENT PROBLEMS . To help you
URGENT SAFETY INFORMATION
. A
HAZARD THAT WILL CAUSE SERIOUS
INJURY OR LOSS OF LIFE .
Page
Information for preventing damage to
equipment .
SMETYGUIDELINES ............................................... 2
WARNING CHART ................................................. 34
DUTYCYCLE ............................................................. 5
GLOSSARY ............................................................... 5
GENERALINFORMATION ........................................ 5
ON-RECEIPTINSPECTION ......................................... 5
DESCRIPTION OF OPERATION .................................. 5
INSTALLATION AND BREAK-IN
pROCEDURES
....................................................... 6-7
Location of Air Compressor .............................. 6
LubricationandOil ........................................... 6
ExtensionCords ................................................ 6
Piping ............................................................... 6
GroundingInstructions ................................... 67
Break-inProcedures ........................................... 7
AdditionalRegulators & Controls ....................... 7
Page
OPERATINGPROCEDURES .................................. 7
Daily Start-up Checklist ..................................... 7
MAINTENANCE ...................................................... 8
Air Filter . Inspectionand Replacement ............. 8
SafetyValve . Inspection ................................... 8
Check Valve Replacement ................................. 8
Motor ................................................................. 8
STORAGE ............................................................... 9
TROUBLESHOOTINGGUIDE ............................. 9-10
AIR COMPRESSOR DIAGRAM ............................. 11
AIR COMPRESSORPARTS LIST .......................... 12
AIR COMPRESSOR PUMP DIAGRAM .................. 13
AIR COMPRESSORPUMP PARTS LIST ............... 14
WARRANIY STATEMENT ......................... Back Cover
f
r SAFETY GUIDELINES . DEFINITIONS i
I
recognizethis information.we use
I symbols to the right. Please read
1 AWARNING I
1 NOTE I
the and pay to IMPORTANT SAFETY INFORMATION . A Informationthat you should pay special
attentionto .
I
HAZARD THAT MIGHT CAUSE SERIOUS
INJURY OR LOSS OF LIFE .
I
these sections .
I
2

IMPORTANT SAFETY INSTRUCTIONS
SAVFTHESFINSTRUCTION s*
0 DRAIN TANK DAILY OR AFTER EACH
- USE. If tank develops a leak, replace it
immediately with a new tank or new
compressor outfit.
IMPROPER OPERATION
OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS
:NJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL WARNINGS AND OPERATING
INSTRUCTIONSBEFORE USINGTHIS EQUIPMENT.
I I=-
NEVER drill into, weld, or MAKE ANY
MODIFICATIONS TO THE TANK
or its
attachments. Never attempt to repair a
damaged or leaking tank. Replacewith a
new tank
1 The tank is designed to withstand
specific operating pressures. NEVER
MAKE ADJUSTMENTS
OR Pm
SUBSTITUTIONS TO alter the
FACTORY SET operating PRESSURES.
-
HAZARD
4ir Tank
m THE FOLLOWING CONDITIONS
COULD lead to a weakening of the
tank,nd RESULT INA VIOLENT
TANK EXPLOSION:
RISK OF BURSTING
1
RISK OF ELECTRIC
SHOCK
RISK OF EXPLOSlOh
OR FIRE
WHATCAN HAPPEN
1. FAILURE TO PROPERLY DRAIN
condensed WATER FROM THE
TANK, causina rust and thinning
of the tank steel.
2. MODIFICATIONS or attempted
repairs TO THE TANK.
Attachments and Accessories
EXCEEDING THE PRESSURE RATING
OF AIR TOOLS, spray guns, air operated
accessories, tires other
INFLATABLES CAN CAUSE THEM TO
EXPLODEor fly apart, and could result
in serious injury.
Your AIR COMPRESSOR is powered b)
electricity. Like anv other electricallv
powered-device,-&it is NOT USED
PROPERLY
it MAY CAUSE
ELECTRICAL SHOCK.
ELECTRICAL GROUNDING: FAILURE
TO PROVIDE ADEQUATE GROUND-
ING TO THIS PRODUCT CQULD
RESULT
IN SERIOUS INJURY OR
DEATH FROM ELECTROCUTION.
SEE GROUNDING INSTRUCTIONS IF
APPLICABLE.
It is normal for ELECTRICAL
CONTACTS within the motor and
pressureswitch
to SPARK WHENEVER
THE COMPRESSOR STARTS OR
STOPS.
3
I
HOW TO PREVENT IT
m - FOR essential CONTROL OF.AIR
PRESSURE, you must INSTALL A
PRESSURE REGULATOR .AND
REGULATED AIR PRESSURE GAUGE
to
the air outlet of your compressor.
recommendation and never exceed the
maximum allowable pressure rating of
attachments. NEVER
USE THE
COMPRESSOR TO INFLATE SMALL
CHILDREN’S TOYS. FOOTBALLS,
Follow the equipment manufacturers
LOW-PRESSURE OBJECTS SUCH
AS
BASKETBALLS. ETC. i
Any ELECTRICAL WIRING OR
REPAIRS required to this product
SHOULD
BE PERFORMED BY
QUALIFIED SERVICE PERSONNEL
OR
a LICENSED ELECTRICIAN, in
accordance with national and local
electrical codes.
MAKE CERTAIN that the ELECTRICAL
CIRCUIT to which the compressor is
connected PROVIDES PROPER
ELECTRICAL
GR 0 UNDING. CORRECT
VOLTAGE, AND ADEQUATE FUSE
~~~
PROTECTI 0 N .
Never operate the compressor outdoors
when it is raining.
Always OPERATE the COMPRESSOR
a well ventilated AREA FREE OF
GASOLINE OR SOLVENT VAPORS.
If spraying flammable materials, LOCATE
COMPRESSOR at least
20 FEET AWAY
FROM SPRAY AREA.
STORE FLAMMABLE MATERIALS in a
secure location AWAY FROM
COMPRESSOR.

IMPORTANT SAFETY INSTRUCTIONS
Read and FOLLOW THE SAFETY
INSTRUCTIONS provided on the label
HAZARD
. ..
:.:.. ,
. ::. ,
. .. ,
"::: .?
..... .
..
RISK TO BREATHING
RISK FROM FLYING
OBJECTS
RISK FROM MOVING
PARTS
l
RISK OF BURN
..
.,
WHAT CAN HAPPEN
The COMPRESSED AIR from your
compressor IS NOT SAFE FOR
BREATHING! The air stream may contain
carbon monoxideor other toxic vapors, or
particles from the tank or other
components.
SPRAYED MATERIALSsuch as paint,
paint solvents, paint remover,
insecticides, weed killers, etc., CONTAIN
HARMFUL VAPORS and poisons.
The COMPRESSED AIR STREAM CAN
cause
soft tissue damage, and can
PROPEL dirt, chips, loose PARTICLES
and small objects at high speed,
resulting in property damage or personal
injury.
The COMPRESSOR CYCLES
AUTOMATICALLY WHEN the
PRESSURESWITCH
IS IN THE ON/
AUTO POSITION! If you attempt repair
or maintenance while the compressor is
operating, or with the switch in the
ON/
AUTO position,you can expose yourself
to moving parts. These MOVING PART:
CAN CAUSE SERIOUS INJURY or
damage
if they come into contact with
you or your clothing.
Contact with HOT PARTS such as the
compressor head or outlet tubes
COULD RESULT IN
A SERIOUS SKIN
BURN.
t
HOW TO PREVENT IT
NEVER INHALE AIR FROM THE
COMPRESSOR, either directly or from a
breathing device connected to the
compressor. WORK
IN AN AREA
equipped WITH GOOD CROSS-
VENTILATION.
or safety data sheet FOR THE
MATERIAL YOU ARE SPRAYING.
USE
A NIOSH/MSHA APPROVED
RESPIRATOR designed
FOR use with
your specific APPLICATION.
ALWAYS WEAR ANSI 287.1
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 QFJ
AND BLEED PRESSURE from the air
line BEFORE attempting maintenance,
ATTACHING TOOLS or acceGories.
2
Always UNPLUG the COMPRESSOR
AND RELEASE AIR PRESSURE
from
the tank and any attachmentsBEFORE
ATTEMPTING any MAINTENANCE
OR
R EPA IR .
NEVER OPERATE the COMPRESSOR
WITH GUARDS or covers which are
damaged or REMOVED.
5-
NEVER TOUCH HOT COMPONENTS
during
or immediately after operation of
the compressor. Do not reach around
protective shrouds or attempt
maintenance until unit has been allowed
to cool.
4

GLOSSARY
CFM: Cubic feet per minute. or airtool. Whenthetank pressuredrops
to a certain levelthe
motor will restart automatically.* The pressure
at which the
motor automatically re-starts
is called "cut-in pressure."
SCFM: Standardcubicfeetperminute; a unitofmeasureof
air delivery.
PSIG: Poundsper square
inch gauge; a unitofmeasure of
pressure.
ASME: American Society of Mechanical Engineers; made,
tested, inspected and registered to meet
the standards of
ASME.
California Code: Unitscomply with California Code 462 (L)
(Z)/(M) (2). Specification/model label is on the side of the
tank on unitsthat comply with California Code.
Cut-In
Pressure: While the motor is off, air tank pressure
drops as you continuetouse your accessory
Cut-OutPressure: Whenyouturnonyourair compressorand
it beginstorun, air pressureinthe air tank beginstobuild. It
builds toa certain high pressure before the motor automati-
cally
shuts off - protectingyour air tank from pressurehigher
than
its capacity. The highpressure at which themotorshuts
off is called "cut-out pressure."
U.L. Listed: Pr0ductswiththeU.LmarkarelistedbyUnderwrit-
ers Laboratories, Inc. (U.L.). Samples of these products have
beenevaluated by U.L. andmeettheapplicable U.L standards
forsafety.
*Seespecificationchart on frontpage.
DUTY CYCLE
AllMakitamanufacturedair compressorsshouldbeoperated on notmorethan a 50% dutycycle. This meansanair compressor
thatpumps air morethan
50% of one hour is consideredmisuse, because theair compressor is undersizedforthe required air
demand. Maximum compressor pumping time per hour is 30 minutes.
GENERAL INFORMATION
This air compressor requires no oil. Nowyou can enjoy all the benefits of having an air compressorwithout ever having to
purchase, add or change oil.
Your air compressor can be usedfor operating paint spray guns, airtools, caulking guns, greaseguns, air brushy, sandblaster,
inflating tires and plastic toys, or spraying weed killers, insecticides, etc. An air pressure regulator
is supplied for these
applications.
Separateairtransformers whichcombinethefunctions ofair regulation and/or moisture and dirtremovalshouldbeusedwhere
applicable.
- I
ON-RECEIPT
DAMAGE: Each air compressor outfit is carefully tested and checked before shipment. With improper handling, dahagemay
Immediatelyuponarrival, checkequipmentfor bothconcealedand visibledamagestoavoid expenses beingincurredtocorrect
such problems. This should be done regardlessofany visible signs of damage tothe shipping container.
If this productwas
shipped directly toyou, report any damagesto carrier and arrangefor inspection ofgoods immediately.
L
result intransit and cause problems in compressoroperation.
,!
DESCRIPTION OF OPERATION
Drainvalve:Thedrainvalveis locatedatthebaseoftheairtank
andisusedto drain condensationatthe endof each use.
MotorThermalOverloadProtector: Theelectricmotorhasan
automaticthermaloverloadprotector.Ifthe motoroverheatsfor
any
reason,thethermaloverload protectorwillshutoff themotor.
The motormustbeallowed to
cool before restarting.
ONlAUTO
- OFF Switch: Turn this switch ON to provide
automatic power to the pressure switch and
OFF to remove
poweratthe end of each use.
Air IntakeFilter: Thisfilter isdesigned tocleanaircoming into
the pump. This filter must alwavs be clean and free from
obstructions. See "Maintenance".
Air Compressor Pump: Tocompress air,the pistonmovesUp
and down inthe cylinder. On the downstroke, air is drawn in
throughthe airintakevalve. Theexhaustvalve remainsclosed.
Ontheupstrokeofthepiston,airiscompressed. Theintakevalve
closes and compressed air is forced out through the exhaust
valve,throughtheoutlettube,throughthecheckvalveandintothe
air tank. Working air
is not available untilthe compressor has
raisedthe airtankpressure abovethat required atthe airoutlet.
Checkvalve: Whentheaircompressor
is operating,thecheck
valve is "open", allowing compressed air to enter the air tank.
Whenthe aircompressor reaches"cut-out" pressure,the check
valve"closes",allowingairpressureto remaininsidetheairtank.
continued rt
5

DESCRIPTION OF OPERATION (cont'd)
PreSsureReleaseValve: Thepressurereleasevalvelocatedon
the side of the pressure switch, is designed to automatically
releasecompressedairfromthecompressorheadandtheoutlet
tubewhen the air compressor reaches "cut-out" pressure or is
Outlet PressureGauge: The outletpressure gauge indicates
the airpressureavailableattheoutletsideof the regulator.This
pressureiscontrolledbytheregulatorandisalwayslessorequal
tothe tank pressure. See "OperatingProcedures".
shut
off. Iftheairisnotreleased,the motor will try tostart,but will
be unable to. The pressure releasevalve allows the motor to
restartfreely.
When the motor stops running, air will be heard
escaping from this Valve for a few seconds. No air should be
heardleakingwhenthe motor is running,or continuous leaking
afterunit reachescut-outpressure.
PressureSwitch: Thepressureswitchautomaticallystartsthe
motorwhentheairtankpressuredropsbelowthefactoryset"cut-
in" pressure.
It stops the motor when the air tank pressure
reachesthe factory set "cut-out" pressure.
SafetyValve: If the pressure switch does not shut
off the air
compressor at
its cut-out pressuresetting, the safety valvewill
protectagainst high pressure by "poppingout" at itsfactory set
pressure(slightlyhigherthanthepressureswitchcut-outsetting).
Tank PressureGauge: Thetankpressuregaugeindicatesthe
reserveair pressure inthe tank.
Regulator: The air pressure coming from the airtank is con-
trolledbytheregulatorknob.Turntheknobclockwisetoincrease
pressureandcounterclockwisetodecreasepressure.To avoid
minor readjustmentafter making achange in pressuresetting,
always approach the desiredpressurefrom a lower pressure.
When reducing from a higherto a lower setting,first reduce to
some
pressurelessthanthatdesired, thenbringuptothedesired
pressure.Dependingonthe air requirementsof eachparticular
accessory, the outlet regulated air pressure may have to be
adjustedwhile you areoperatingthe accessory.
- INSTALLATION AND BREAK-IN PROCEDURES -
.. ..
location of theAir Compressor
Locatethe air compressor in a clean, dry and well ventilated
area.Theairfiltermustbekeptclearof obstructionswhichcould
reduce air delivery of the air compressor. 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
compressor head and shroud are designedto allow for proper
cooling. If humidity is high, an air filter can be installedon the
air outlet adapter to remove excessive moisture. Follow the
instructionspackaged with the air filter for proper installation.
Lubrication and Oil
Thisunitneedsnolubricationoroiling.
Piping (cont'd)
If a pipelineis necessary,usepipethat isthesame size asthe
airtank outlet. Pipingthat istoo smallwill restrictthe flowof air.
If piping is over 100 feet long, use the next larger size. Bury
undergroundlinesbelowthefrost line and avoidpocketswhere
condensation can gather and freeze. Apply pres;ure before
underground lines are coveredto make sure all pipejoints are
free of leaks.
GROUNDING INSTRUCTION
Extension Cords
Toavoidvoltagedrop,powerloss,andoverheatingof the
motor, use an extra air hose instead of an extension cord.
Low voltage can cause damage to the motor.
RISK
OF ELECTRICALSHOCK! In theeventota
shortcircuit, groundingreducestheriskofshock
by providing an escape wire for the electric
current. This air compressor must be properly
grounded.
If an extensioncordmustbe used:
useonly a3-wire extensioncordthat hasa3-bladeground-
ingplugand a3-slotreceptaclethatwill acceptthe plugon
the air compressor.
make surethe extensioncordis ingood condition.
the extensioncordshould be nolongerthan50feet.
the minimumwire size is 12gauge (AWG).(Wire size
increasesas gaugenumberdecreases.
10 AWG and 8 AWG
may
also be used. DO NOT USE 14 AWG or 16 AWG.)
Piping
The aircompressor isequippedwith a cord havinga grounding
wirewith an appropriategroundingplug.Theplugmustbeused
withanoutletthathasbeeninstalledandgroundedinaccordance
with
all local codes and ordinances.The outlet must have the
sameconfigurationastheplug.Seeillustration.DONOTUSEAN
ADAPTER.
Inspectthe plugandcord beforeeach use.
Do not useif
there are signs
of damage.
IMPROPER GROUNDING CAN RESULT IN
ELECTRICAL SHOCK.
PlasticorPVCpipe
is notdesignedfor usewith
compressed air. Regardless of its indicated
pressure rating, plastic pipe can burstfrom air
pressure, Useonlymetalpipeforairdistribution
lines.
Do notmodifytheplugthat hasbeenprovided. If itdoes
notfitthe availableoutlet,thecorrectoutletshouldbe
installedbyaqualifiedelectrician. continued
IC
6.

INSTALLATION AND BREAK-IN PROCEDURES (cont'd)
GROUNDING INSTRUCTION (cont'd)
If repairing or replacing cord or plug, the grounding wire must
be kept separate from the current-carryingwires. Never con-
nect the grounding wire to a flat blade plug terminal. The
groundingwire has insulationwith anoutersurfacethat
is green
- with or without yellow stripes.
If these grounding instructionsare notcompletely understood,
or if indoubtastowhetherthecompressoris properlygrounded,
have the installationchecked by a qualified electrician.
120 Volt Modete
240 bit Models
AdditionalRegulatorsandControls
Sincethe air tankpressure is usually greaterthan thatwhich is
needed,aseparate
regulatorisusuallyemployed tocontroltheair
pressureaheadof any individualairdrivendevice.
Separate air transformers which combine the function
of air
regulation, moisture and dirt removal should be used where
applicable.
NOTE
It isnotuncommonfortheairtank to containsome
water from the testing of thetank atthefactory.
Break4 n Procedures
Seriousdamagemayresultifthefollowing break-
in instructionsare not closely followed.
This procedureisrequired:
1. Beforethe air compressor is putintoservice.
2. Whenthe checkvalveisreplaced.
3. Whenacompletecompressor pumpisreplaced.
a.
b.
c.
d.
e.
Setthe pressureswitchleverto the''OFF'' position.
Plugthe powercord intothe correctbranchcircuit
receptacle.
Turnthe drainvalveclockwise,opening itfully,to
preventairpressurebuild-upinthetank.
Movethe pressureswitch leverto "OWAUTO".
The compressorwill start.
Runthecompressorfor
15 minutes.Makesure
thedrainvalve,isopenandthere is
littletankpressurebuild-up.
After
15 minutes,closethe drainvalve byturning
it completelycounterclockwise.The air rdceiver
will fill to cut-outpressure and the motywill stop.
The compressorisnow readyfor use.
f.
OPERATING PROCEDURES
Daily Start-up Checklist
When you are finished:
7.
#
1. Beforeattaching air hose or accessories, make sure the 6. Set the pressureswitch lever to "OFF. J.
pressureswitch lever isset to "OFF"andthe air regulator
or shut-off valve is closed. Using the air
tool or accessory, bleedthe tank pressure
down
to approximately 20 psi.
Drainwater from airtankbyopeningdrainvalve onbottom
of tank.
2. Attach hose and accessories. 8. Removethe air tool or accessory.
9.
TOO MUCHAIR PRESSURE CAUSES A HAZARDOUS
RISK OF BURSTING.CHECK THEMANUFACTURER'S
MAXIMUM PRESSURERATING FOR AIR TOOLS AND
ACCESSORIES. THE REGULATOR OUTLET PRES-
SURE MUST NEVER EXCEED THE MAXIMUM PRES-
SURE RATING.
WATER
WILL CONDENSEINTHEAIRTANK.
IF NOT DRAINED, WATER WILL CORRODE
AND WEAKEN THE AIR TANK CAUSING A
RISK OF AIR TANK RUPTURE.
3.
Turn the pressure switch lever to "ON/AUTO and allow
tank pressureto build. Motorwill stopwhen tank pressure
reaches "cut-out" pressure.
Openthe regulatorbyturningitclockwise.Adjust the regu-
lator to the correct pressure setting. Your compressor is
readyfor use.
Alwaysoperate theaircompressorinwell-ventilatedareas;
freeofgasolineorothersolventvapors. Do notoperatethe
compressornearthe spray area.
NOTE
If draincockvalveisplugged, releaseallair
pressure. The valve can then be removed,
cleaned,then reinstalled.
4.
10. After the water has been drained,close the drain cock or
drain valve. The air compressor can now be stored.
5.
7

MAINTENANCE
UNIT CYCLES AUTOMATICALLYWHEN POWER IS ON. WHEN DOINGMAINTENANCE,YOU MAY BE EXPOSEDTO
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 PRES-
SURE.
To ensure efficient operation and longer lie of the air compressoroutfii, a routinemaintenancescheduleshould be prepared and
followed.Thefolbwing routine
maintenancescheduleisgearedto anoutfiit inanormalworkingenvironmentoperatingonadailybasis.
If necessary,theschedule should be modifiedto suitthe conditions underwhich your compressor is used.The modificationswill
dependuponthe hoursofoperationandtheworkingenvironment.Compressoroutfiksinanextremelydirtyand/orhostileenvironment
will requirea greaterfrequency of all maintenancechecks. Lubricatecompressor motor (if required)according
to manufacturer's
instructions,which areattachedtoyour motor.
ROUTINE MAINTENANCE SCHEDULE
..
... .
. ... .. .-, ..
. .. .... ..
,:. , .:
. ...
..... .
....
Daily:
1. Drain water from the air tank, any moisture separators
ortransformers.
2. Checkfor any unusual noise and/or vibration. valves.
3. Manually check all safety valves to make sure they are
operating properly.
5. Inspectairlinesand fittingsfor leaks;correctas necessary.
EachYear of Operationor ifaProblem
is Suspected:
Check condition of air compressor pump intake and exhaust
Checkcondition of check valve. Replace if damaged or worn
4. Inspect air filter, replace if necessary. out.
SERVICE INSTRUCTIONS
Air Filter-Inspection and Replacement
4. Removethepressurereleasetubeandfitting. -'
5.
Unscrewthe check valve (turncounterclockw$e) using a
socket wrench.
6.
Checkthatthevalve disc movesfreely insidethe
checkvalveandthatthe springholdsthedisc inthe
upper, closed position.The check valve may be cleaned
with a strongsolvent.
Apply sealant to the check valve threads. Reinstallthe
check valve (turn clockwise).
Keepthe airfilter clean at alltimes.
Do notoperatethe
compressorwiththeairfilterremoved.
A dirty air filter will not allow the compressor
to operate at full
capacity. Beforeyou usethe compressor,checktheairfilter to
besure
it is clean.
7.
If it isdirty, simply pull it outand replace.
8.
9.
10. Replacetheshroud.
Replacethepressurereleasetubeandfitting.
Replacetheoutlettube andtightentopandbottomputs.
Motor
Safety Valve - Inspection
IF THE SAFETY VALVE DOES NOT WORK PROP-
ERLY, OVER-PRESSURIZATION MAY OCCUR,
CAUSINGAIR TANK RUPTUREOR AN EXPLOSION.
VALVE TO MAKESURETHAT THE SAFETY VALVE
OPERATES FREELY. IF THE VALVE
IS STUCK OR
DOES NOT OPERATE SMOOTHLY, IT MUST BE
RE-
PLACEDWITH THE SAMETYPE OF VALVE.
The motorhasan automaticresetthermaloverloadprotector. If
the motoroverheatsfor any reason,the overload protectorwill
shutoffthemotor.Themotormustbe allowedtocooldown before
restarting. The compressor will automatically restart after the
OCCASIONALLY PULLTHE RING ON THE SAFETY
motprcoo~s.
If theoverloadprotectorshutsthe motor off frequently,check
for a possible voltage problem. Low voltage can
also be SUS-
pectedwhen:
1.
2.
Units With External Brass Check Valve
Replacement
1. Releaseallair pressurefromairtank andunplugoutfit.
2. Removeshroud.
3. Loosenthetopandbottomnutoftheoutlettubeandremove.
The motordoes notget uptofullpoweror speed.
Fusesblowoutwhen startingthe
motor; lightsdim
andremaindimwhenmotoris startedand isrunning.
8

STORAGE
Before you store the air compressor, make sure you do the
following:
1. Reviewthe“Maintenance”and”OperatingProcedures”
sectionsandperformmaintenanceas necessary. Be sure
to drainwaterfrom the airtank.
2.
Protectthe electricalcordandair hosefrom damage(such
asbeingsteppedonorrunover),Windthemlooselyaround
thecompressorhandle.
Storethe air compressorinaclean anddry location.
TROUBLESHOOTING
GUIDE
PERFORMING REPAIRS MAY EXPOSE VOLTAGE SOURCES, MOVING PARTS OR COMPRESSED AIR
SOURCES. PRIOR TO AlTEMPTING ANY REPAIRS, UNPLUG THE
COMPRESSOR AND BLEED OFF TANK AIR PRESSURE.
PERSONAL INJURY MAY OCCUR.
PROBLEM
Excessivetankpressure-safety
valve pops
off.
Air leaks at fittings.
Airleaksatorinsidecheckvalve.
Air leaks at pressureswitch re-
lease valve.
Air leaksinairtank or at airtank
welds.
Air leaks between head anc
valve plate.
Pressure reading on the regu
lated pressure gauge dropc
when an accessory is used.
Air leak from safety valve.
:AWE
’ressure switchdoes notshut off mo.
or when compressor reaches “cut,
~t“pressure.
Pressure switch “cut-out” too high.
Tube fittingsare not tight enough.
~~ ~
lefective or dirty check valve.
3efective pressure switch
release valve.
Defective check valve.
Defective air tank.
Leaking gasket.
It
is normalfor “some”pressuredropt’
occur.
Possible defect in safety valve.
9
CORRECTION
Movethe pressure switchleverto the “OFF“ position.
If the outfit doesn’t shut off, unplug. If the electrical
contacts are welded together, replace the pressure
switch.
If thecontacts aregood, check
to see if the pininthe
pressure releasevalve is stuck.
If it does not move
freely, replace the vaive.
Returnthe outfiito anauthorizeddealerto check and
adjust, or replace switch.
Tighten fittings where air can be heard escaping.
Check fittinas with soaw water solution.
DO NOT
OVER-TIGHTEN.
J
A defectivecheckvalve resutts in a constant air leak
at the pressurereleasevalvewhere there
is pressure
in the tank and the compressor is shut off. Remove
and cleanor replace check valve. DO NOT OVER-
TIGHTEN.
Remove and replace the release valve.
.
c
&
A defective check valve results in a constant air leak
at the pressure releasevalve when there is pressure
inthe tank and the compressor is shut off. Remove
and clean or replace check valve. DO NOT OVER-
TIGHTEN.
Air tank must be replaced. Do not repairthe leak.
DO NOT DRILLINTO, WELD OR OTHERWISE
MODIFYAIR TANK OR ITWILLWEAKEN. THE
TANK CAN RUPTURE OR EXPLODE.
Torque headscrewsto 10 ft. Ibs. If this does notstop
leak, replace gasket.
Ifthere is an excessiveamount
of pressuredropwhen
the accessory is used, adjust the regulatorfollowing
the instructionson page 6.
NOTE
Adjust the regulated pressure under flow conditions
(while accessory is being used).
Operate safety valve manually by pulling on ring. If
valve stillleaks,itshould be replaced.

TROUBLESHOOTING GUIDE (Continued)
hessure release valve on pressur
switchhasnotunloadedheadpressurc
PROBLEM
KnockingNoise
Compressor is not supplying
enough air
to operate accesso-
ries.
Dirty or damaged regulator intern;
parts.
.. ,
. .I ... ..
.. .,
X..' ::
... .
... .. . , . ..
CORRECTION
__ ~
Motorwill notrun.
Removeandclean,or replace.
'..,,':,[
..
....
.. 1 ..
..
..
~~
-~
Decreaseamount of air usage.
Checktheaccessoryairrequirement.
If it ishigherthan
the SCFMor pressuresuppliedbyyour air compres-
sor, you need alargercompressor.
Cleanor replaceairintakefilter.
Do not operatetheair
compressorinthe paintsprayarea.
Checkand replaceif required.
Removeandclean,or replace.
Tightenfittings. (SeeAirLeaksSectionofTroubleshoot-
ingGuide.)
Letmotorcooloffandoverloadswitchwillautomatically
eset.
Regulatorknob hascontinuou!
air leak. Regulator
will not shu
off at air outlet.
CAUSE
tefective check valve.
estrictedair intakefilter.
Volongedexcessive useof air.
:ompressor isnotlargeenoughfor air
equirement.
oleinhose.
heckvalve restricted.
,ir leaks.
Aotor overload protection switch ha:
ripped.
'ankpressureexceedspressureswitc!
cut-in" pressure.
Nronggaugewireorlengthofextensioi
:ord.
;heck valve stuck open.
-oose electricalconnections.
Possibledefectivecapacitor.
Paintsprayon internalmotorparts.
Possibledefectivemotor.
Fuseblown,circuit breakertripped.
hotorwillstartautomaticallywhentankpressuredrops
ielow"cut-in" pressureof pressureswitch.
;heck for propergaugewire andcordlenah.
?emoveandclean,or replace.
;heck wiring connection inside pressure switch and
erminalboxarea.
a"
Return to anAuthorizedWarranty ServiceCenterfor
inspectionor replacement,
if necessary.
Have checked at an Authorized Warranty 'Service
Center.
Do notoperatethe compressor in hepaint
spray area. Seeflammablevaporwarning. '
Have checked at an Authorized Warranty Service
Center.
1.
Check fuse box for blown fuse and replace, if
necessary. Reset circuitbreaker. Do not use a
fuseorcircuitbreakerwith higherratingthanthat
specifiedforyour particularbranchcircuit.
Check for proper fuse; only "Fusetron" type
T
fusesareacceptable.
Checkfor low voltage conditions and/or proper
extensioncord.
Disconnectthe other electricalappliances from
circuit or operate the compressor on its own
branchcircuit.
Bleedthe line by pushing the lever on the pressure
switchto the
"off" position; if the valvedoes notopen,
replaceit.
2.
3.
4.
Replace regulator.
10

AIR COMPRESSOR DIAGRAM
Kf/
NO.
17
18
23
TORQUE
95 to 105 in. Ibs.
50 TO 60 in. Ibs.
SNUG
23
- 24
25
\
34
29
11

KEY
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
28
29
30
31
32
33
34
35
36
37
38
39
40
41
PARTNUMBER DESCRIPTION
.-
, .. .
... .. . . ... ...
./ _.,. ..
. , :., .....
. .....
..... .
..
. ,.
..
CAC-1080
AC-0046
SS-655-ZN
CAC-1121
AC-0426
SSF-1001-1
SSP-7813
AC-0406
SSF-3156
TA-4405
AC-0261
SSP-7811
SS-8553
CAC-4290-3
AC-0249
ACG-18
91895680
SSF-953-ZN
SSP-480
SST-5314-1
TIA-4150
SSW-7367
SSF-607
AGO173
CAC-4296-1
AC-0266
AC-0404
SUDL-403-1
SSP-6021
SSG-3105
ACG-19
AC-0253
AC-0400
AC-0403
SSP-7821-1
AC-0270
CAC-1419
AC-0397
AC-0430
AC-0231
TOOL TRAY
REAR SHROUD
HEXNUT 1/4"20UNC (2USED)
SHROUD BRACKET(2USED)
PUMP ASSEMBLY
NUTSLEEVE ASSY 3/8"
OUTLETTUBE
TANK
HANDLE GRIP
NUTSLEEVEASSY 1/4" (2 USED)
CONNECTOR BODY
CHECK VALVE
PRESSURE RELIEFTUBE
CUP SADDLE MOUNT (2 USED)
SCREW 10
x 5/8
NIPPLE
RUBBERBUMPER
(4 USED)
SAFETYVALVE
STRAINRELIEF BUSHING (2 USED)
SCREW (4 USED)
QUICKCONNECTOR
REGULATOR
GAUGE
(2 USED)
MANIFOLDSWITCH
POWER CORDASSEMBLY
REDUCERBUSHING
ISOLATOR (3 USED)
SOLBERGFILTER
FRONTSHROUD
HEAD COVER
NUT
PLUG
PRESSURE SWITCH COVER
FINGERGUARD
DRAINVALVE
NIPPLE
'
SCREW 10-32 (2 USED)
SCREW 10-9X.50 (2 USED)
SCREW 1/4-20
x .75 (2USED)
O-RING
12

AIR COMPRESSOR PUMP DIAGRAM
58-
lwl I
I
66 I 100 to 120 In. Lbs. I
67
59uz>
$/70
w7’
v7*
69
,
-62
66
65 \
13

AIR COMPRESSOR PUMP PARTS LIST
.. . , ... ,
. ..
.. .. ,
.... .
,:.,
..... .. . . , .. .
."
KEY
NO.
54
55
56
*J 57
58
8J 59
.' 60
*J 61
62
65
66
67
69,
*J 70
71
*J 72
73
PARTNUMBER
AC-0252
SSF-589
SSF-927
ACG-45
AC-0032
SSG-8156
---
---
Ma9045
SSF-615
AC-0140
AC-0108
SSF-586
SSF-3158-1
---
-
DAC-161
KK-4315
AGO281
D ESCRl PTlO N
Head
Stud1/4"-20
x 1 1/4"(2 used)
Screw 1/4-20
x 11/4"(2used)
CLRing
Valveplateassembly(includesvalves,restrictors
& screws)
oring
Connectingrodassembly
Cylindersleeve(positionlocatingmarktowardmotor)
Motor
EccentricFlywheelBearingAssy.
Screw 1/4-20unc-2A
Fan
Screw 1/4-20unc
x .75
Screw10-24
X .75T25Tom
ConnectingRodCap
CompressionRing
Shim
1
/6
NOTILLUSTRATED
PressureReliefValve
AirFilterReplacement
* Keys57,59,60,61,70,71, and 72are purchased as part of KK-4835piston/cylinderkit.
J Keys57,59,61,70 and72can be purchased as partof K-0058cylindersleeve/compression
ringkit.
..
..
...
. .. ..
. .. . .. ..
.. . ..
.....
.. .
.. ..
. ., ...
..
14

SERVICE NOTES
,
-
i
15

-.
..:.. :. i
.... :,
... ., .
.... ....
. ...
_. ,
... ..
.. ..... . ..
OWNERS MANUAL FOR
Permanently Lubricated Air Compressor
MODEL NO.
MAC1 200

MANUAL DEL OPERADOR PARA
COMPRESORDEAIRE DE LUBRICACIONPERMANENT€
MODEL0 NO.
MAC1 200
TABLA DE ESPECIFICACIONES
Modelo No
Potencia
DesplazamientoCFM
SCFM
@ 40 psig
SCFM
@ 90 psig
Presi6ndearranque
Presiondecode
Orificio
Carreradelpiston
Voltajemonofasico
Amperaje amax. Presi6n
TamaAodetanque
Aprobadopour UL
y CUL
Tipodefusible
,
MAC1 200 -
2 HP P
11.9
8.3
6.1
100PSI
125PSI
2
38"
1.35" 4
120 L
Fusetron TipoT
15Amps.
4 Galones
RequerimientoMinimodeCircuit0
15 Amps
* Es preferibleuninterruptorde circuito. Usar solo unfusible o interruptordecircuitodelmismo
amperajequeelcircuitoenel cualesta operando el compresor de aire. Sielcompresordeaire esta
conectadoa uncircuitoprotegidoporfusibles, usar
solo fusiblesderetardo.
I

TABLA DE CONTENIDOS
PAUTASDESEGURIDAD - DEFlNlClONES
A PELIGRO I lA CUIDADO
Este manual contiene informacibn
que es importante que usted sepa
y
entienda. Esta informacion se INFORMACIONDESEGURlDPDURGENTE-UNRlESGO Informacibn para evitar dahos a1
relaciom con la protecci6n de su
I
QUEPUEDECAUSAR DdOS PERSONALESSERIOS 0
equipo
SEGURIDAD y la PREVENCION DE
PROBLEMAS AL EQUIPO. Para
ayudarle a entender esta
[ AADVERTENCIA 1 \A NOTA 1
informacibn usamos 10s siguientes
simbolos. Porfavor leere*temanual
RIESGO QUEPUEDE CAUSAR DANOS PERSONALES atencibn especial.
y prestar atencibn a estas secciones.
LA PERDIDA DE
INFORMACIONDE SEGURIDAD IMPORTANTE UN lnformacidn
a laquese debe predar
SERIOS LA PgRDIDA DE VIDA.
i
P6gina
Pagina
-..
. ::. :...I
':;. ..::. .:
...., "
...
..... :I ..fl
......
.-
PAUTASDESEGURIDAD ........................................... 2
TmmDEADVERTENClAS .................................... 3-4
GLOW10 ............................................................... 5
ClCLODElRABAJO .................................................. 5
INFORMACION GENERAL ........................................ 5
INSPECCION ALRECIBIR .......................................... 5
DESCRIPCION DELAOPERACION ............................ 5
INSTALACIONY PROCEDIMIENTOSPARAEL
ASENTAMIENTO
................................................... 6-7
Ubicaci6n delCompresordeAire ....................... 6
Aceite
y Lubricacion ........................................... 6
Cordones deExtension ...................................... 6
Tuberias
............................................................. 6
lnstruccionespara ConexionaTierra
.............. 67
Reguladores y ControlesAdicionales .................. 7
Procedimiento para el Asentamiento ................. 7
PROCEDIMIENTOSPARAOPERAR ............................ 7
lnspecciones DiariasparaArrancar ..................... 7
MANTENIMIENTO .................................................... 8
FiltrodeAire - Inspection y Remplazo ................ 8
Valvula deSeguridad - Inspection ...................... 8
RemplazodelaValvula deCheque0 .................. 8
Motor ................................................................ 8
ALMACENNE .......................................................... 9
GU~APARADETECCI~N DE PROBLEMAS ............. 9-10
DIAGRAMADELCOMPRESORDEAlRE ................... 11
LlSTADEPARTES DELCOMPRESORDEAlRE ........... 12
DIAGRAMADE LA BOMBADEL
COMPRESORDEAlRE
.............................................. 13
LISTADE PARTESDE LA BOMBADEL
COMPRESORDEAlRE
.............................................. 14
-
4"
COMPROMISO DE GARANT~A ............. ultima Piigina
..
. .,
....
....
....... ...... ,
.. .,, .....
..... .. ,.
., .
....
2

- INSTRUCCIONES IMPORTANTES DE SEGURIDAD -
CONSERVARESTASINSTRUCCIONES
bnque de Aire
US SIGUIENTES CONDICIONES PODRiAN
conducir at debilitamiento
del tanque DANDO
I DEOPERACI~N
RIESGO
TODO CABLEADO o REPARAC~~N que esta
unidad requiera DEBE REAfIZARLA UN
PERSONALCALIFICADO DE SERVICIO
0 un
ELECTRICISTA LICENCIADO, acatando 10s
codigos electricosnacionaly local.
ASEGURARSE que el CIRCUITO EL~CTRICO
alcualesthconectado el compresor,
EjZ
CONECTADO A TIERRA EN FORMA
APROPIADA
Y PROVEA EL VOLTAJE
CORRECT0
Y TENGA PROTECCION
ADECUADAMEDIANTE FUSIBLES.
Nunca operar el compresor en el exterior
cuandoesteIloviendo.
RIESGO DE EXPLOSION
RIESGO DE
CHOQUE
ELECTRICO
RIESGO DE INCENDIO
o EXPLOSION
NTES DE USARESTA UNIDAD.
QUEPUEDE SUCEDER
COMO , RESULTADO UNA VIOLENTA
1. OMlTlR DRENAR APROPIADAMENTE EL
AGUA condensadaque oxidarli eltanque
deacero, debilitindolo
y adelgarando sus
paredes.
EXPLOSIONDELTANQUE:
2. MODlFlCAClONES o intentosdereparara
TANOUE.
3. MODlFlCAClONES no auto,rizadas 4
CONTROL DE PRESION, VALVULA DE
SEGURIDAD
0 a cualquier
COMWNENTEQUE CONTROLE LA PRESION
deltanque.
lditamentos v Accesonos
1 EXCEDER LA CAPACIDAD DE PRESION DE M
HE RRAM I E NTAS NE u MATICAS, pi stola 5
rociadoras,accesor,ios para aire, neumaticos ,
Ilantas, Y otros ARTlCULOSINFIABLESPUEDEh
HACERLOS EXPLOTAR
o salir disparado!
causandolesiones
y datios serios
El COMPRESOR DE AlRE operaconelectricidad
Como cualquier otro dispositivo electrica
USAADECUADAM
E NTE .
PUEDE CAUSAR CHOQUE EL~CTRICO SI NO s
0
CONEXION A TIERRA: EL NO HACE
ADECUADAMENTE
IA CONEXION A TIERR
DEL PRODUCTO, PUEDE RESULTAR
El
LESIONES SERIAS 0 MUERTE DEBIDO ,
ELECTROCUCION, VER W INSTRUCCIONESD
CONEXIONA TIERRA APLICABLES.
r
Es noTalque el motory el INTERRUPTOR D1
PRESION emitan CHISPAS CUANDO E
COMPRESOR ARRANQUE Y PARE.
COMO EVITARLO
DRENAR EL TANQUE DIARIAMENTE 0
DESPUES DE CADA USO. Si rele produce
una fuga al tanque, reemplazarlo
inmediatamente porotrotanque nuevo
o
un compresor nuevo.
NUNCA taladrar, soldar NI HACER
MODlFlCAClONALGUNA AL TANOUE
ni a
sus aditamentos. Nunca intentarreparar
un tanque daiiado o con fugas.
Reemplazarlocon
un tanque nuevo.
El tanque est6 diseiiado para resistir las
presionesdetrabajo especificadas. NUNCA
SUBSTITUIR PARTES NI ALTERAR LAS
REGULACIONESNI PRESIONES de trabaio
PREFIJADOSEN FABRICA.
PARAUNCONTROLesencialDE LAPRESION
DE AIRE, el cliente debe INSTALAR UN
DE PRESIONREGUIADADE
AlRE en la salida
REGULADOR DE PRESI~N Y UN MEDIDOR
de airedel compresor. *'
I Siempreobservarlas recodnendaciones del
fabricante del
equip0 y nunca wceder la
Dresion maxima especificada para
un
9
iditamento. NUNCAUSARELCOMPRESOR
PARA INFIAROBJETOS PEQUENOSDE BAJA
PRESION TALES COMO JUGUETES DE
NINOS.PELOTAS DE FUTBOL, BALONCESTO,
-~ ~
SiempreOPERAR el COMPRESOR DE AlRE
EN AREAS bien ventiladas, SIN VAPORES
DE GASOLINA NIDE OTROS SOLVENTES.
Si se rocian materiales inflamables,
COLOCAR EL COMPRESOR por
lo menos a
6m (20') DE AREA DE PULVERIZACION.
GUARDAR LAS SUBSTANCIAS
INFIAMABLES en un lugar seguro
LEJOS
DEL COMPRESOR.
3

!
.. ..
INSTRUCCIONES IMPORTANTES
DE SEGURIDAD (Cont.)
-~
RIESGO
RIESGO A LA
RESPIRAUON
RIESGO DE OBJECTOS
PROPULSADOS
RIESGO DE PIE=
MOWBLES
I I I
RIESGO QUEMADUW
OUE PUEDESUCEDER
El AIRE COMPRIMIDOproducidoporlaunidad
iNO ES SEGURO PARA RESPIRAR! El chorro de
aire puede contener monoxido de carbono,
otros vaporestoxicos, particulasprovenientes
deltanque
u ovos componentes.
W SUBSTANCIAS PULVERIZADAStales como
pinturas, solventes de pintura, removedores
de pintura, insecticidas, herbicidas, etc.,
CONTIENEN VAPORES DANINOS y
VENENOSOS.
~~~ ~-~ ~
El CHORRO DE AlRE COMPRIMIDO puede
daiiar el tejido humano blando
y puede
IMPULSARtierra, PARTkUWsueltas
y objetos
pequeiiosavelocidades altas, causando daiios
materiales
o personales.
iEl COMPRESOR DE AIRE ENTRA EN
FUNCIONAMIENTO AUTOMATICAMENTE
CUANDO EL INTERRUPTOR DE PRESI~N EST^
EN LA POSICION DE ON/AUTO (PRENDIDO,
AUTOMATICO)! lntentar reparar
o hacei
mantenimientocuandoelcompresorest&er
operacion o conelinterruptor de presionen I;
posicion de ON/AUTO, puedeexponerlo a la!
piezas movibles. Estas PIEZAS MOVIBLE!
PUEDENCAUSARSERIOS DANOS PERSONAE!
si entran en contactoconusted o su ropa.
El contacto con PlEW CALIENTEStalescomi
elcabezaldelcompresor
o 10s tubosdesalid,
PUEDENCAUSARUNAQUEMADURASERIA
El
LA PIEL.
COMOEWTARLO
1 NUNCA INHALAR EL AlRE PROVENIENTE
DEL COMPRESOR, ya sea directamente o a
traves de
un dispositivo para respirar
conectadoa1 compresor. TRABAIAR EN UN
AREA BlEN VENTILADA.
Leer
y SEGUIR W INSTRUCCIONES DE
SEGURIDAD provistas en las etiquetas y
hobsdedatosdeseguridadDELMATERIAL
OUE
SE ESTA PULVERIZANDO. USAR UN
RESPIRADOR APROBADO POR NIOSH/
MSHA
y diseiiado para la APLICACION
especifica.
AJ usarelcompresor, SIEMPRE USAR WAS
DE SEGURIDAD con protectores laterales
que CUMPLAN CON
LA NORMA ANSI
NUNCA APUNTAR la boquilla o el
ROClADORhaciapartesdelcuerpo, HAClA
OWPERSONAS o animales.
SiempreAPAGAR el COMPRESOR Y ALNlAR
LA PRESldN de la linea de aire ANTES de
intentardarlemantenimiento o CONECTAR
HERRAMIENTAS o accesonos. ,
Siempre DESCONECTAR la UNIDAD Y
ALlVlAR LA PRESION DEL ThQUE y de
cualquier accesorio ANTES DE HACER
REPARACION
ES 0 MANTENIMIENTO.
287.1.
NUNCA OPERAR el COMPRESOR SIN LOS
COBERTORES de la correa
o cuando 10s
cobertoresestandaiiados.
k
NUNCA TOCAR LOS COMPONENTES
CALIENTES durante
o inmediatamente
despues de la operacion del compresor.
Nuncaintroducir las manos pordetras de
lascubiertas protectoras niintentardarle
mantenimiento alcompresorhastaque
se
hallaenfriado.
4