Porter-Cable CPF4515 User manual

Oilfree
Compressors
CPF6020
IMPORTANT
Please make certain that the person who isto use
this equipmer_ earefutty reads and understands
these instructions before starting operations.
The Model and Serial No. p_ateis located on the
frame. Record these numbers in the spaces below
and retain for future r_erence.
Model No,
Type
Serial No.
part No, D20814-004
1iii_!!i%i!!_i!_ii_i_;i_!!i_i_i_i_i;ii_;ii_!_!_!;!!_i_;_!_!_ii_;:_;!;!ii!i!i¸

SAFETY GUIDELINES - DEFINITIONS
This manual contains information that is important for you to know and understand. This infor-
mation relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To
help you recognize this information, we use the symbols below. Please read the manual and
pay attention to these sections.
[FI,_TL_T:XlJ | [o]_
DANGER indicatesan imminently
hazardous situation which, if not
avoided, will result in death or
[*'T_'tlH[a]_
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in
CAUTION indicates apotentially
hazardous situation which, if not
avoided, may result in minor or
moderate iniurv.
CAUTION used without the safety
alert symbol indicates apotentially
hazardous situation which, if not
avoided, _result in
d_.
Call our Toll Free Number 1-888-559-8550, to obtain the location of the nearest Autho-
rized Service Center for ordering repair parts and for warranty repairs.
When ordering repair parts from your local Authorized Service Center, always give the
following information:
•Model number of your compressor
•Part number and description of the item you wish to purchase
Retain Original Sales Receipt as Proof of Purchase for Warranty Repair Work.
IMPORTANT SAFETY INSTRUCTIONS
When using electric tools, basic safety precautions
should always be followed to reduce the risk of fire, electric shock
and personal injuw, including the following:
READ AND FOLLOW ALL INSTRUCTIONS,
This tool was designed for certain applications. Porter-Cable strongly recommends
that this tool NOT be modified and/or used for any application other than for which
it was designed. If you have any questions relative to its application DO NOT use
the tool until you have written Porter-Cab[e and we have advised you.
Technical Service Manager
Porter-Cable Corporation
4825 Highway 45 North
P.O. Box 2468
Jackson, TN 38302-2468
2*ENG

IMPORTANT SAFETY INSTRUCTIONS (cont'd)
SAVE THESE INSTRUCTIONS
IMPROPER OPERATION OR MAINTENANCE OF THiS PRODUCT COULD RESULT IN SERIOUS iNJURY
AND PROPERTY DAMAGE, READ AND UNDERSTAND ALL WARNINGS AND OPERATING
INSTRUCTIONS BEFORE USING THIS EQUIPMENT.
HAZARD
RISK OF EXPLOSION OR FIRE
WHAT CAN HAPPEN HOW TO PREVENT IT
IT IS NORMAL FOR ELECTRICAL CONTACTS
WITHIN THE MOTOR AND PRESSURE SWITCH TO
SPARK.
IF ELECTRICAL SPARKS FROM COMPRESSOR
COME INTO CONTACT WITH FLAMMABLE
VAPORS, THEY MAY IGNITE, CAUSING FIRE OR
EXPLOSION.
RESTRICTING ANY OF THE COMPRESSOR
VENTILATION OPENINGS W1LL CAUSE SERIOUS
OVERHEATING AND COULD CAUSE FIRE.
UNATTENDED OPERATION OF THIS PRODUCT
COULD RESULT IN PERSONAL INJURY OR
PROPERTY DAMAGE.
RISK OF BURSTING
ALWAYS OPERATE THE COMPRESSOR IN A WELL
VENTILATED AREA FREE OF COMBUSTIBLE
MATERIALS, GASOLINE OR SOLVENT VAPORS.
IF SPRAYING FLAMMABLE MATERIALS, LOCATE
COMPRESSOR AT LEAST 20 FEET AWAY FROM
SPRAY AREA. AN ADDITIONAL LENGTH OF HOSE
MAY BE REQUIRED,
STORE FLAMMABLE MATERIALS IN A SECURE
LOCATION AWAY FROM COMPRESSOR.
NEVER PLACE OBJECTS AGAINST OR ON TOP
OF COMPRESSOR. OPERATE COMPRESSOR IN
AN OPEN AREA AT LEAST 12 INCHES AWAY FROM
ANY WALL OR OBSTRUCTION THAT WOULD
RESTRICT THE FLOW OF FRESH AIR TO THE
VENTILATION OPENINGS.
OPERATE COMPRESSOR IN A CLEAN, DRY, WELL
VENTILATED AREA, DO NOT OPERATE UNIT
INDOORS OR IN ANY CONFINED AREA.
ALWAYS REMAIN IN ATTENDANCE WITH THE
PRODUCT WHEN IT IS OPERATING.
_BJ_: THE FOLLOWING CONDITIONS COULD LEAD TO AWEAKENING OF THE TANK, AND RESULT
IN A VIOLENT TANK EXPLOSION AND COULD CAUSE PROPERTY DAMAGE OR SERIOUS INJURY.
WHAT CAN HAPPEN
1 FAILURE TO PROPERLY DRAIN CON-
DENSED WATER FROM THE TANK,
CAUSING RUST AND THINNING OF THE
STEEL TANK,
2. MODIFICATIONS OR ATTEMPTED REPAIRS
TO THE TANK.
3. UNAUTHORIZED MODIFICATIONS TO THE
UNLOADER VALVE, SAFETY VALVE, OR
ANY OTHER COMPONENTS WHICH
CONTROL TANK PRESSURE.
4. EXCESSIVE VIBRATION CAN WEAKEN THE
AIR TANK AND CAUSE RUPTURE OR
EXPLOSION.
ATTACHMENTS S ACCESSORIES:
EXCEEDING THE PRESSURE RATING OF AIR
TOOLS, SPRAY GUNS, AIR OPERATED
ACCESSORIES, TIRES AND OTHER INFLATABLES
CAN CAUSE THEM TO EXPLODE OR FLY APART,
AND COULD RESULT IN SERIOUS INJURY.
HOW TO PREVENT IT
DRAIN TANK DAILY OR AFTER EACH USE. IF TANK
DEVELOPS A LEAK, REPLACE IT IMMEDIATELY
WITH A NEW TANK OR REPLACE THE ENTIRE
COMPRESSOR.
NEVER DRILL INTO, WELD, OR MAKE ANY
MODIFICATIONS TO THE TANK OR ITS
ATTACHMENTS,
THE TANK IS DESIGNED TO WITHSTAND SPECIFIC
OPERATING PRESSURES. NEVER MAKE
ADJUSTMENTS OR PARTS SUBSTITUTIONS TO
ALTER THE FACTORY SET OPERATING
PRESSURES.
FOR ESSENTIAL CONTROL OF AIR PRESSURE,
YOU MUST INSTALL A PRESSURE REGULATOR
AND PRESSURE GAUGE TO THE AIR OUTLET OF
YOUR COMPRESSOR. FOLLOW THE EQUIPMENT
MANUFACTURERS RECOMMENDATION AND
NEVER EXCEED THE MAXIMUM ALLOWABLE
PRESSURE RATING OF ATrACHMENTS. NEVER
USE COMPRESSOR TO INFLATE SMALL LOW-
PRESSURE OBJECTS SUCH AS CHILDREN'S
TOYS, FOOTBALLS, BASKETBALLS. ETC.
3-ENG

IMPORTANT SAFETY INSTRUCTIONS (cont'd)
RISK FROM FLYING OBJECTS
WHAT CAN HAPPEN
THE COMPRESSED AIR STREAM CAN CAUSE
SOFT TISSUE DAMAGE TO EXPOSED SKIN AND
CAN PROPEL DIRT, CHIPS, LOOSE PARTICLES
AND SMALL OBJECTS AT HIGH SPEED,
RESULTING IN PROPERTY DAMAGE OR PERSONAL
INJURY.
HOW TO PREVENT IT
ALWAYS WEAR ANSI Z87.1 APPROVED SAFETY
GLASSES WITH SIDE SHIELDS WHEN USING THE
COMPRESSOR,
NEVER POINT ANY NOZZLE OR SPRAYER TOWARD
ANY PART OF THE BODY OR AT OTHER PEOPLE
OR ANIMALS.
ALWAYS TURN THE COMPRESSOR OFF AND
BLEED PRESSURE FROM THE AIR HOSE AND
TANK BEFORE ATTEMPTING MAINTENANCE,
ATTACHING TOOLS OR ACCESSORIES,
RISK TO BREATHING
WHAT CAN HAPPEN
THE COMPRESSED AIR FROM YOUR
COMPRESSOR IS NOT SAFE FOR BREATHINGI
THE AIR STREAM MAY CONTAIN CARBON
MONOXIDE, TOXIC VAPORS OR SOLID PARTICLES
FROM THE TANK.
SPRAYED MATERIALS SUCH AS PAINT, PAINT
SOLVENTS, PAINT REMOVER, INSECTICIDES,
WEED KILLERS, CONTAIN HARMFULVAPORS AND
POISONS.
HOW TO PREVENTIT
ALWAYS OPERATE AIR COMPRESSOR OUTSIDE
IN A CLEAN, WELL VENTILATED AREA, AVOID
ENCLOSED AREAS SUCH AS GARAGES,
BASEMENTS, STORAGE SHEDS, WHICH LACK A
STEADY EXCHANGE OF AIR. KEEP CHILDREN,
PETS AND OTHERS AWAY FROM AREA OF
OPERATION,
NEVER INHALE AIR FROM THE COMPRESSOR
EITHER DIRECTLY OR FROM A BREATHING DEVICE
CONNECTED TO THE COMPRESSOR.
WORK IN AN AREA WITH GOOD CROSS-
VENTILATION, READ AND FOLLOW THE SAFETY
INSTRUCTIONS PROVIDED ON THE LABEL OR
SAFETY DATA SHEETS FOR THE MATERIAL YOU
ARE SPRAYING. USE A NIOSH/MSHA APPROVED
RESPIRATOR DESIGNED FOR USE WITH YOUR
SPECIFIC APPLICATION.
RISK OF ELECTRICAL SHOCK
WHAT CAN HAPPEN
YOUR AIR COMPRESSOR IS POWERED BY
ELECTRICITY. LIKE ANY OTHER ELECTRICALLY
POWERED DEVICE, IF IT IS NOT USED PROPERLY
IT MAY CAUSE ELECTRIC SHOCK.
REPAIRS ATTEMPTED BY UNQUALIFIED
PERSONNEL CAN RESULT IN SERIOUS INJURY OR
DEATH BY ELECTROCUTtON.
ELECTRICAL GROUNDING: FAILURE TO PROVIDE
ADEQUATE GROUNDING TO THIS PRODUCT
COULD RESULT IN SERIOUS INJURY OR DEATH
FROM ELECTROCUTION, SEE GROUNDING
INSTRUCTIONS.
HOW TO PREVENTIT
NEVER OPERATE THE COMPRESSOR OUTDOORS
WHEN IT IS RAINING OR IN WET CONDITIONS.
NEVER OPERATE COMPRESSOR WITH COVER
COMPONENTS REMOVED OR DAMAGED,
ANY ELECTRICAL WIRING OR REPAIRS
REQUIRED ON THIS PRODUCT SHOULD BE
PERFORMED BY AUTHORIZED SERVICE
CENTER PERSONNEL IN ACCORDANCE WITH
NATIONAL AND LOCAL ELECTRICAL CODES.
MAKE CERTAIN THAT THE ELECTRICAL CIRCUIT
TO WHICH THE COMPRESSOR IS CONNECTED
PROVIDES PROPER ELECTRICAL GROUNDINGj
CORRECT VOLTAGE AND ADEQUATE FUSE
PROTECTION.
4-ENG

IMPORTANT SAFETY INSTRUCTIONS (cont'd)
RISK FROM MOVING PARTS _
WHAT CAN HAPPEN
MOVING PARTS SUCH AS THE PULLEY,
FLYWHEEL, AND BELT CAN CAUSE SERIOUS
INJURY IFTHEY COM EINTO CONTACT WITH YOU
OR YOUR CLOTHING.
ATTEMPTING TO OPERATE COMPRESSOR WITH
DAMAGED OR MISSING PARTS OR A3-I-EMPTING
TO REPAIR COMPRESSOR WITH PROTECTIVE
SHROUDS REMOVED CAN EXPOSE YOU TO
MOVING PARTS AND CAN RESULT IN SERIOUS
INJURY,
HOW TO PREVENTIT
NEVER OPERATE THE COMPRESSOR WITH
GUARDSORCOVERSWHICHAREDAMAGEDOR
REMOVED.
ANY REPAIRS REQUIRED ON THIS PRODUCT
SHOULD BE PERFORMED BY AUTHORIZED
SERVICE CENTER PERSONNEL.
RISK OF BURNS I_i
WHAT CAN HAPPEN HOW TO PREVENT IT
TOUCHING EXPOSED METAL SUCH AS THE NEVERTOUCHANYEXPOSEDMETALPARTSON
COMPRESSOR HEAD OR OUTLET TUBES, CAN COMPRESSOR DURING OR IMMEDIATELY AFTER
RESULT IN SERIOUS BURNS. OPERATION. COMPRESSOR WILL REMAIN HOT
FOR SEVERAL MINUTES AFTER OPERATION.
DO NOT REACH AROUND PROTECTIVE SHROUDS
OR ATTEMPT MAINTENANCE UNTIL UNIT HAS
BEEN ALLOWED TO COOL,
RISK OF FALLING
WHAT CAN HAPPEN HOW TO PREVENT IT
A PORTABLE COMPRESSOR CAN FALL FROM A ALWAYS OPERATE COMPRESSOR IN A STABLE
TABLE, WORKBENCH OR ROOF CAUSING SECURE POSITION TO PREVENT ACCIDENTAL
DAMAGE TO THE COMPRESSOR AND COULD MOVEMENT OF THE UNIT. NEVER OPERATE
RESULT IN SERIOUS INJURY OR DEATH TO THE COMPRESSOR ON A ROOF OR OTHER ELEVATED
OPERATOR OR BYSTANDERS. POSITION. USE ADDITIONAL AIR HOSE TO
REACH HIGH LOCATIONS.
RISK OF PROPERTY DAMAGE WHEN
TRANSPORTING COMPRESSOR
(Fire, Inhalation, Damage
to Vehicle Surfaces)
WHAT CAN HAPPEN HOW TO PREVENT IT
OIL CAN LEAK OR SPILL AND COULD RESULT ALWAYS PLACE COMPRESSOR ON A PROTECTIVE
IN FIRE OR BREATHING HAZARD, SERIOUS MAT WHEN TRANSPORTING TO PROTECT
INJURYOR DEATH CAN RESUL_ OILLEAKSWILL AGAINST DAMAGE TO VEHICLE FROM LEAKS.
DAMAGE CARPET, PAINT OR OTHER SURFACES REMOVE COMPRESSOR FROM VEHICLE
INVEHtCLESORTRAILER8. IMMEDIATELY UPON ARRIVAL AT YOUR
DESTINATION.
ESW-gg-- gi2G,_gg
5oENG

GLOSSARY
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per minute; a unitof measure of air delivery.
PSlG: Pounds per square inch gauge; a unit of measure of pressure.
ASME: American Society of Mechanical Engineers; made, tested, inspected, and
registered to meet the standards of ASME.
California Code: Unit may comply with California Code 462 (l) (2)/(M) (2),
Specification/model label ison the side of the tank on units that comply with
California Code.
Cut-In Pressure: While the motor is off, air tank pressure drops as you continue to
use your accessory or air tool. When the tank pressure drops to a certain low level
the motor will restart automatically. The low pressure at which the motor
automatically restarts iscalled "cut-in pressure."
Cut-Out Pressure: When you turn on your air compressor and it begins to run, air
pressure in the air tank begins to build. It builds to a certain high pressure before
the motor automatically shuts off -protecting your air tank from pressure higher
than its capacity. The high pressure at which the motor shuts off is called "cut-out
pressure,"
Code Certification: Productsthat bear one or more of the following marks: UL,
CUL, ETL, CETL, have been evaluated by OSHA certified independent safety
laboratories and meet the applicable Underwriters Laboratories Standards for
Safety. DUTY CYCLE
Porter-Cable air compressors should be operated on not more than a 50% duty
cycle. This means an aLrcompressor that pumps air more than 50% of one hour is
considered misuse, because the aircompressor is undersized for the required air
demand. Maximum compressor pumping time per hour is 30 minutes.
SPECIFICATIONS
Model No. CPF4515 CPF6020
Horsepower Peak 4.5 6
Bore 2.375" 2.375
Stroke 1.35" 1.35"
* Voltage-Single Phase 120 120
**Minimum Branch Circuit Requirement 15 amps 15 amps
* Fuse Type Time Delay Time Delay
Air Tank Capacity (Gallon) 15 ASME 20 ASME
Approximate Cut-in Pressure 110 PSIG 110 PSIG
Approximate Cut-out Pressure 135 PSIG 135 PSIG
SCFM @40 PSIG 8.0 8.3
SCFM @ 90 PSIG 5.7 5.8
* _ This air compressor can be operated on a 15 amp circuit if:
1. Voltage supply to circuit is normal.
2. Circuit is not used to supply any other electrical needs (lights, appliances, etc.)
3. Extension cords comply with specifications in owners manual.
4. Circuit is equipped with 15 amp circuit breaker or 15 amp time delay fuse.
If any of the above conditions cannot be met, or if operation of the air compressor
repeatedly causes interruption of the power it may be necessary to operate it from
a20 amp circuit. It is not necessary to change the cord set.
* *A circuit breaker is preferred, Use only a fuse or circuit breaker that isthe same rating
as the branch circuit on which the air compressor is operated, If the air compressor is
connected to a circuit protected by fuses, use dual element time delay fuses.
6-ENG

DESCRIPTION OF OPERATION
Drain Valve (not shown): The drain valve is located at the base of the air tank and
is used to drain condensation at the end of each use.
Motor Thermal Overload Protector (not shown): The electric motor has an
automatic thermal overload protector. Ifthe motor overheats for any reason, the
thermal overload protector will shut off the motor. The motor must be allowed to
cool before restarting.
ON/AUTO -OFF Switch (A) Fig. 1: Turnthis A_
switch ON to provide automatic power to the
pressure switch and OFF to remove power at
the end of each use.
Air Intake Filter (not shown): Thisfilter is
designed to clean air coming intothe pump.
This filter must always be clean and
ventilation openings free from obstructions.
See "Maintenance".
Air Compressor Pump {not shown): To
compress air,the piston moves up and down
in the cylinder. On the downstroke, air is
drawn in through the air intake valves. The
exhaust valve remains closed. On the Fig. 1
upstroke of the piston, air is compressed.
The intake valves close and compressed air isforced out through the exhaust
valve, into the outlet tube, through the check valve and into the air tank. Working
air is notavailable untilthe compressor has raisedthe air tank pressure above that
required at the air outlet.
Check Valve (not shown): When the air compressor isoperating, the check valve
is"open", allowing compressed air to enter the airtank. When the aircompressor
reaches "cut-out" pressure, the check valve "closes", allowing air pressure to
remain inside the airtank.
Pressure Release Valve (not shown): The pressure release valve located on the
side of the pressure switch, is designed to automatically release compressed air
from the compressor head and the outlet tube when the air compressor reaches
"cut-out" pressure or is shut off. The pressure release valve allows the motor to
restart freely.When the motor stoos runnina, air will be heard escaDino from this
valve for a few seconds. No air should be heard leaking when the motor is runnina.
or continuous leakinq after unit reaches cut-out pressure.
Pressure Switch (B) Fig. 1: The pressure switch automatically starts the motor
when the air tank pressure drops below the factory set "cut-in" pressure. It stops
the motor when the air tank pressure reaches the factory set "cut-out" pressure.
Safety Valve (C) Fig. 1: If the pressure switch does not shut off the air compressor
at its cut-out pressure setting, the safety valve will protect against high pressure by
"popping out" at its factory set pressure (slightly higher than the pressure switch
cut-out setting).
Outlet Pressure Gauge (D) Fig. 1: The outlet pressure gauge indicates the air
pressure available at the outlet side of the regulator.This pressure is controlled by
the regulator and is always less than or equal to the tank pressure.
Tank Pressure Gauge (E) Fig. 1: The tank pressuregauge indicates the reserve air
pressure in the tank,
Regulator (F) Fig. 1: The air pressure coming from the airtank is controlled by the
regulator knob, Turn the knob clockwise to increase pressure and counterclockwise
to decrease pressure. To avoid minor readjustment after making achange in
pressure setting, always approach the desired pressure from a lower pressure.
When reducing from a higher to a lower setting, first reduce to some pressure less
than that desired, then bring up to the desired pressure. Depending onthe air
requirements of each particularaccessory, the outlet regulated air pressure may
have to be adjusted while you are operating the accessory,
7-ENG

INSTALLATION
Installing Handles, Wheel, and Rubber Foot (Fig. 2)
I_ THE WHEELS AND HANDLE DO NOT PROVIDE
ADEQUATE CLEARANCE, STABILITY OR SUPPORT FOR PULLING
THE UNIT UP AND DOWN STAIRS OR STEPS. THE UNIT MUST BE
LIFTED, OR PUSHED UP A RAMR
1. Submerge handle grip (A) intowarm soapy water to make installation easier.
Remove handle grip (A)from soapy water and slide onto handle (B).
2. Position legs of handle (B) inside compressor saddle. Align holes in handle
legs with holes in saddle. Using a 3/8" wrench to secure handle in place, using
the four screws provided (two screws (C), through each side of saddle).
m_"_T_"_ It may be necessary to brace or support one end of the
unit when attaching the wheels and the rubber feet, because the air
compressor will have a tendency to tip.
3, Place shoulder bolt through wheel (D) and position it into the top holeof the
mounting bracket. Thread nut onto shoulder bolt and tighten firmly with a 9/16"
wrench. Repeat to install second wheel.
4. Clean and dry air tank leg (E) opposite wheels. Remove the protective paper
strip from the adhesive backed rubber foot strip. Position rubber foot strip to
the bottom of leg and press firmly into place.
Fig. 2
8-ENG

Location of the Air Compressor
Locate the air compressor in aclean, dry, and well-ventilated area. The air filter
must be kept clear of obstructions which could reduce air flow to 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 designed to allow for proper cooling. If humidity is high, an air filter
can be installed on the air outlet adapter to remove excessive moisture. Follow the
instructions packaged with the air filter for proper installation.
Lubrication and Oil
This unit needs no lubrication or oiling.
Extension Cords
Toavoid voltage drop, power loss, and overheating to 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 a3-wire extension cord that has a 3-blade grounding plug and a 3-slot
receptacle that will accept the plug on the extension cord.
•make sure the extension cord is in good condition.
• the extension cord should be no longer than 50 feet.
• the minimum wire size is 12 gauge (AWG). (Wire size increases as gauge
number decreases. 10 AWG and 8 AWG may also be used. DO NOT USE 14
AWG or 16 AWG.)
Voltage and Circuit Protection
Refer to the specification chart for voltage and circuit protection requirements of
your compressor. Use only a fuse or circuit breaker that isthe same rating as the
branch circuit on which the air compressor isoperated. Ifthe compressor is
connected to acircuit protected by fuses, use only dual element time delay fuses,
Piping
Plastic or PVC pipe is not designed for use with
compressed air, Regardless of its indicated pressure rating, plastic
pipe can burst from air pressure. Use only metal pipe for air
distribution lines.
If a pipe line is necessary, use pipe that isthe same size asthe airtank outlet,
Piping that is too small will restrict the flow of air. If piping is over 100 feet long, use
the next larger size. Bury underground lines below the frost line and avoid pockets
where condensation can gather and freeze. Apply pressure before underground
lines are covered to make sure all pipe joints are free of leaks.
A flexible coupling needs to be installed between the outlet valve and the main air
distribution line to allow for vibration.
9-ENG

GROUNDING INSTRUCTIONS
RISK OF ELECTRICAL SHOCK! In the event of a short
circuit, grounding reduces the risk of shock by providing an escape
wire for the electric current. This air compressor must be properly
grounded.
Ifthese grounding instructions are not completely understood, or if in doubt as to
whether the compressor is propedy grounded, have the installation checked by a
qualified electrician. The air compressor is equipped with a cord having a
grounding wire with an appropriate grounding plug. The plug must be used with an
outlet that has been installedand grounded in
accordance with all localcodes and ordinances. The
outlet must have the same configuration as the plug.
See Fig. 3. DO NOT USE AN ADAPTER.
inspect the plug and cord before each use. Do not
use if there are signs of damage.
II_JT_'_I Improper grounding can result
in electrical ehockl
Do not modify the plug that has been provided. If it
does not fit the available outlet, the correct outlet
should be installed by a qualified electrician.
If repairing or replacing cord or plug, the grounding
wire must be kept separate from the current-carrying
wires. Never connect the grounding wire to a flat
blade plug terminal. The grounding wire has
insulation with an outer surface that is green - with or
without yellow stripes.
120 Volt Models
White
15 Amp Plug Outlet
Grounded_
%El
Ground_l _ _
Pin
Fig. 3
Additional Regulators and Controls
Since the airtank pressure is usuallygreater than that which is needed, a separate
regulator is usually employed to contro[the air pressure ahead of any individual air
driven device.
10-ENG

BREAK-IN PROCEDURES
Serious damage may result ifthe following break-in
instructions are not closely followed,
This procedure is required before the air compressor isput into service. (before the
hose is installed), the check valve is replaced, or acomplete compressor pump is
replaced.
The procedure:
1. Make sure the pressure switch lever is in the "OFF" position.
2. Plug the power cord into the correct branch circuit receptacle.
3. Open the drain valve fully to permit air to escape and prevent air pressure build
up in the air tank during the break-in period.
4. Move the pressure switch lever to "ON/AUTO". The compressor will start.
5, Run the compressor for 15 minutes. Make sure the drain valve is open and
there is minimal air pressure build-up in tank.
6. After 15 minutes, close the drain valve.
7. Move the pressure switch lever to "ON/AUTO".The air receiver will fill to cut-out
pressure and the motor will stop.
The compressor is now ready for use.
OPERATING PROCEDURES
Daily Start-Up Checklist
1. Before attaching air hose or accessories, make surethe ON/AUTO lever is set to
"OFF" and the air regulator is closed.
2. Attach hose and accessories.
TOO MUCH AIR PRESSURE CAUSES A HAZARDOUS
RISK OF BURSTING. CHECK THE MANUFACTURER'S MAXIMUM
PRESSURE RATING FOR AIR TOOLS AND ACCESSORIES. THE
REGULATOR OUTLET PRESSURE MUST NEVER EXCEED THE
MAXIMUM PRESSURE RATING.
3. Turnthe ON/AUTO lever to "AUTO" and allow tank pressure to build. Motor will
stop when tank pressure reaches "cut-out" pressure.
4. Open the regulator by turning it clockwise. Adjust the regulator to the correct
pressure setting. Your compressor is ready for use.
5. Always operate the air compressor in well-ventilated areas;free of gasoline or
other combustible vapors. Ifthe compressoris being used to operate a sprayer
DO NOT use near the spray area..
When you are finished:
6. Set the "ON/AUTO" lever to "OFF".
7. Turn the regulator counterelockwise and set the outlet pressure to zero.
8. Remove the air tool or accessory.
9. Pull ring on safety valve allowing airto bleed from the tank until tank pressure is
approximately 20 psi. Release safety valve ring.
10.Drain water from air tank by opening drain cock valve on bottom oftank.
WATER WILL CONDENSE IN THE AIR TANK. IF NOT
DRAINED, WATER WILL CORRODE AND WEAKEN THE AIR TANK
CAUSING A RISK OF AIR TANK RUPTURE.
11.After the water has been drained, close the drain cock or drain valve. The air
compressor can now be stored. NOTE
Ifdrain cock valve is plugged, release all air pressure. The valve can then
be removed, cleaned, then reinstalled.
11-ENG

MAINTENANCE
Unit cycles automatically when power is on. During
maintenance, you could be exposed to voltage sources, compressed
air, moving parts, or hot surfaces. Personal injuries can occur. Unplug
the unit and bleed off all air tank pressure and allow unit to cool
before doing any maintenance or repair, Never operate the unit with
the belt guard removed.
To ensure efficient operation and longer life of the air compressor unit, a routine
maintenance schedule should be prepared and followed. The following routine
maintenance schedule isgeared to an unit in a normal working environment
operating on a daily basis. If necessary, the schedule should be modified to suit the
conditions under which your compressor is used. The modifications will depend
upon the hours of operation and the working environment. Compressor units in an
extremely dirLyand/or hostile environment will require agreater frequency of all
maintenance checks.
ROUTINE MAINTENANCE SCHEDULE
Daily:
1. Pull ring on safety valve allowing air to bleed from the tank untiltank pressure is
approximately 20 psi. Release safety valve ring.
2. Drain water frem the air tank, any moisture separators, or transformere,
3. Check for any unusual noise and/or vibration.
4, Manually check safety valve to make sure of proper operation.
5. Inspect air filter and replace if necessary.
6. Inspect air lines and fittings for leaks; correct as necessary.
Each Year of Operation or if a Problem is Suspected:
Check condition of air compressor pump intake and exhaust valves. Replace if
damaged or worn out. SERVICE INSTRUCTIONS
Air Filter - Inspection and Replacement
Keep the air filter clean at all times. Do not operate the compressor with the air
filter removed. Adirty air filter will not allow the compressor to operate at full
capacity. Before you use the compressor, check the air filter to be sure it is clean. If
it is dirty, simply pull it out. You may wash it with amild detergent and warm water,
or replace it.
Safety Valve -Inspection
I_ IF THE SAFETY VALVE DOES NOT WORK PROPERLY,
OVER-PRESSURIZATION MAY OCCUR, CAUSING AIR TANK
RUPTURE OR AN EXPLOSION. DAILY PULL THE RING ON THE
SAFETY VALVE TO MAKE SURE THAT THE SAFETY VALVE OPERATES
FREELY. IF THE VALVE IS STUCK OR DOES NOT OPERATE
SMOOTHLY, IT MUST BE REPLACED WITH THE SAME TYPE OF
VALVE.
Check Valve Replacement
1. Release all air pressure from air tank and unplug unit.
2. Remove shroud.
3. Loosen the top and bottom nuts and remove the outlet tube.
4, Remove the pressure release tube and fitting.
12oENG

5. Unscrew the check valve using a socket wrench.
6. Check that the valve disc moves freely inside the check valve and that the
spring holds the disc in the upper, closed position. The check valve may be
cleaned with a strong solvent.
7. Apply sealant to the check valve threads. Reinstall the check valve.
8. Replace the pressure release tube and fitting.
9. Replace the outlet tube and tighten top and bottom nuts.
10. Replace the shroud.
Motor
The motor has an automatic reset thermal overload protector. If the motor
overheats for any mason, the overload protector will shut off the motor. The motor
must be allowed to cool down before restarting. The compressor will automatically
restart after the motor cools.
If the overload protector shuts the motor off frequently, check for a possible voltage
problem. Low voltage can also be suspected when:
1. The motor does not get up to full power or speed.
2. Fuses blow out when starting the motor; lights dim and remain dim when motor
is started and/or is running.
Motor -Wiring Diagram
The motor connection diagram is located on the side of motor,
STORAGE
Before you store the air compressor, make sure you do the following:
1. Review the Maintenance section on the preceding pages and perform sched-
uled maintenance as necessary.
2. Set the "ON/AUTO" lever to "OFF".
3. Turn the regulator counterclockwise and set the outlet pressure to zero.
4. Removetheairtooloraccessory.
5. Pull ring on safety valve allowing air to bleed from the tank until tank pressure is
approximately 20 psi. Release safety valve ring.
6. Drain water from air tank by opening drain cock valve on bottom of tank.
I_ WATER WILL CONDENSE IN THE AIR TANK, IF NOT
DRAINED, WATER WILL CORRODE AND WEAKEN THE AIR TANK
CAUSING A RISK OF AIR TANK RUPTURE,
7. After the water has been drained, close the drain cock or drain valve.
NOTE
Ifdrain cock valve isplugged, release all air pressure. The valve can then
be removed, cleaned, then reinstalled.
8. Protect the electrical cord and air hose from damage (such as being stepped on
or run over). Wind them loosely around the compressor handle. (If so equipped)
Store the air compressor in aclean and dry location.
13-ENG

TROUBLESHOOTING GUIDE
IPERFORMING REPAIRS MAY EXPOSE VOLTAGE
SOURCES, MOVING PARTS OR COMPRESSED AIR SOURCES.
PERSONAL INJURY MAY OCCUR. PRIOR TO ATTEMPTING ANY
REPAIRS, UNPLUG THE AIR COMPRESSOR AND BLEED OFF ALL AIR
TANK AIR PRESSURE.
PROBLEM
Excessive tank
pressure - safety
valve pops off.
Air leaks at fittings.
Air leaks at or inside
check valve.
Air leaks at pressure
switch release
valve,
Air leaks in air tank or
at air tank welds.
CAUSE
Pressure switch does not shut
off motor when compressor
reaches "cut-out" pressure.
Pressure switch "cut-out" too
high.
Tube fittings are not tight
enough.
Malfunctioning or dirty check
valve.
Maffunctioning pressure switch
release valve.
Malfunctioning check valve.
Damaged air tank.
Leaking o-ring.
It is normal for "some"
)ressure drop to occur.
Air leaks between
head and valve
plate.
Pressure reading on
the regulated
pressure gauge
drops when an
accessory isused.
CORRECTION
Move the pressure switch lever to
the "OFF" position, If the unit
doesn't shut off, and the electrical
contacts are welded together,
replace the pressure switch.
Contact an authorized service
center to check and replace
)ressure switch.
Tighten fittings where air can be
heard escaping. Check fittings with
soapy water solution. DO NOT
OVER-TIGHTEN,
A malfunctioning check valve
results in a constant air leak at the
_ressure release valve when there
is pressure in the tank and the
compressor is shut off. Drain tank
then remove and clean or replace
check valve. DO NOT OVER-
TIGHTEN.
Remove and replace the release
valve.
Amalfunctioning check valve
results in a constant air leak at the
3ressure release valve when there
ISpressure in the tank and the
compressor is shut off. Drain tank
then remove and clean or replace
check valve. DO NOT OVER-
TIGHTEN.
DO NOT
DRILL INTO, WELD OR
OTHERWISE MODIFY AIR
TANK OR IT WILL
WEAKEN. THE TANK CAN
RUPTURE OR EXPLODE.
TANK MUST BE RE-
PLACED.
Torque head screws to 8 ft. Ibs. If
this does not stop leak, replace o-
ring.
If there is an excessive amount of
_ressure drop when the accessory
is used, adjust the regulator
following the instructions on page
7. NOTE: Adjust the regulated
)ressure under flow conditions
while accessory is being used).
14-ENG

PROBLEM
Motor will not run or
restart.
CAUSE
Motor overload protection
switch has tripped.
Tank pressure exceeds
lressure switch "cut-in"
)ressure,
Wrong gauge wire or length of
extension cord.
Check valve stuck open.
Loose electrical connections.
Possible malfunctioning motor
or starting capacitor.
Paint spray on internal motor
3arts.
:use blown, circuit breaker
tripped.
Pressure release valve on
pressure switch has not
unloaded head pressure.
CORRECTION
Let motor cool off and overload
switch will automatically reset.
Motor will start automatically when
tank pressure drops below "cut-in"
pressure of pressure switch.
Check for proper gauge wire and
cord length.
Remove and clean, or replace.
Check wiring connection inside
Jressure switch and terminal box
area.
Contact an Authorized Warranty
Service Center for inspection or
replacement, if necessary.
Have checked by an Authorized
Warranty Service Center. Do not
operate the compressor in the paint
spray area, See flammable vapor
warning.
1. Check fuse box for blown fuse
and replace, if necessary. Reset
circuit breaker. Do not use a
fuse or circuit breaker with
higher rating than that specified
for your particular branch circuit.
2. Check for proper fuse; only time
delay fuses are acceptable.
3. Check for low voltage
conditions and/or proper
extension cord.
4. Disconnect the other electrical
appliances from circuit or
operate the compressor on its
own branch circuit.
Bleed the line by pushing the lever
on the pressure switch to the "off"
_osition; if the valve does not open,
replace it.
15-ENG

PROBLEM
Air leak from safety
valve.
Knocking Noise.
Compressoris not
supplying enough air
to operate
accessories.
Regulator knob has
continuous air leak.
Regulator will not
shut off air outlet.
CAUSE CORRECTION
Possibledefectinsafetyvalve,
Malfunctioning check valve.
Prolonged excessive use of air.
Compressor is not large
enough for air requirement.
Restricted air intake filter.
Hole in hose.
Check valve restricted.
Air leaks.
Pressure release valve on
pressure switch has not
unloaded head pressure.
Damaged regulator.
Operate safety valve manually by
pulling on ring. If valve still leaks, it
should be replaced,
Remove and clean, or reptace.
Decrease amount of air usage.
Check the accessory air
requirement. If it is higher than the
SCFM or pressure supplied by your
a_rcompressor, you need a larger
compressor,
Clean or replace air intake filter. DO
not operate the air compressor with
the filter removed. See page 12.
Check and replace if required.
Remove and clean, or replace.
Tighten fittings. (See Air Leaks
Section of Troubleshooting Guide.)
Replace regulator.
16*ENG

ACCESSORIES
Accessories can be found at the store from which the unit was purchased or at
alocal hardware store.
FILTERS, REGULATORS, LUBRICATORS
_ILTER/
REGULATOR
Regulates air pressure and
removes moisture, oil and
other debts from the air line.
Protects fools from
rust and is essential when
spray painting. Locate as
close fo the tool as passible.
_EGULATOR
Controls air
prlsssur8
downstream
and/oric
secondary
feeder lines.
_UBRICATOR OR
INLINE OILER
Administers oil
into the air line.
Reduces excessive
wear and rusting In
tools. DO not use when
i_ spray paibtmg,
PLUMBING COMPONENTS
_T-FrrTING_CORNECT_RS Ideal for _'anch_g
Connects components that have air lines.
similar NPT threads; Male or Femaib.
Combines components that have different
NPT threads; Male or Female.
INLINE VALVE
360 °SWIVEL CONNECTOR OnlOff valw. Controls air
Eliminates hose twlet and improves tool handling, flow;, not air pressurL
HOSE QUICK-CONNECTS
3/3" I.D. HOSE 1/4" COIL HOSE Together they provide quick and
Ideal for increasi Serf-retracting and lightweight, easy attechment/separatibn of
. . r_ .Less bulk than regular hoses, components within the air line.
woricng distance m h:gh
CFM applications. Ideal secondary hose line DO not mbcdifferent styles of
in lower CFM applications, bodies/plugs.
17-ENG

LIMITED WARRANTY
PORTER-CABLE CORPORATION warrants to the original purchaser that each new air
compressor and service part is free from defects in material and workmanship and agrees to
repair or replace under this warranty any defective product or part as follows from the original
date of purchase.
5 YEARS - Limited warranty on 2-stage oil-free air compressor pumps that operate at
1725 RPM and 1 year limited warranty on all other parts.
3YEARS - Limited warranty on oil-lubricated air compressor pumps and t year limited
warranty on all other parts.
I YEAR - Limited warranty on all other air compressor products.
90 Day - Service parts
Engine warranties are the responsibility of the engine manufacturer. Warranties of
merchandise sold by Porter-Cable which has been manufactured by and identified as the
product of another company arethe responsibility of the manufacturer of that product.
THIS WARRANTY IS NOT TRANSFERABLE AND DOES NOT COVER
Products sold damaged or incomplete, sold "as is", sold reconditioned or used as rental
equipment.
Delivery, installation or normal adjustments explained in the owner's manual.
Damage or liability caused by shipping, improper handling, improper installation,
incorrect voltage or improper wiring, improper maintenance, improper modification, or the
use of accessories and/or attachments not specifically recommended by PORTER-
CABLE for the tool.
Repairs necessary because of operator abuse or negligence, or the failure to install,
operate, maintain and store the product according to the instructions in the owner's
manual.
Damage caused by cold, heat, rain, excessive humidity, corrosive environments and
materials, or other contaminants.
Expendable items that become worn during normal use such as drain valves, fuses,
filters, belts, air cleaners, spark plugs, engine oil and pump oil.
Cosmetic defects that do not interfere with tool functionality.
Freight costs from customer to Porter-Cable.
Repair and transportation costs of products or parts determined not to be defective.
ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE
THAT MAY RESULT FROM ANY DEFECT, FAILURE OR MALFUNCTION OF THE
PRODUCT. Some states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF
ORIGINAL PURCHASE. Some states do not allow limitations on how long an implied
warranty lasts, so the above limitations may not apply to you.
WARRANTY SERVICE is available by delivering or shipping the defective product or part
to any Porter-Cable authorized warranty service location. To determine the nearest authorized
warranty service location, callthe toll free number, 1-888-559-8550, 24 hours a day, 7 days a
week. Specific instructions regarding servicing arrangements and scheduling may vary
depending on the type and size of the product and the availability of repair parts.
DO NOT return the defective product to the retailer.
Retain the original cash register sales receipt as proof of purchase for warranty work.
Only Air compressors with 60 and 80 gallon tanks will be inspected at the site of
installation.
The customer should contact Porter-Cable directly if the purchaser does not receive
satisfactory results from the authorized warranty service center.
PORTER+(HBLE°
Porter-Cable Corporation
4825 Highway 45 North
RO. Box 2468
Jackson, TN 38302-2468
1-888-559-8550
18-ENG