Porter-Cable CPL55GH8W User manual

Instruction
manual
MODEL
CPL55GH8W
Oillube
Compressor
o learn more about Porter-Cable
visit our website at:
http://www.porter-cable.com
IMPORTANT
Please make certain that the person who is to use
this equipment carefully reads and understands
these instructions before starting operations.
PORTER+CRBLEo
PROFESSIONAL POWER TOOLS
The Model and Serial No plate is located on the
frame Record these numbers in the spaces below
and retain for future reference
Model No
Type
Serial No
3opyright © 2000 PORTER CABLE Corporation P;trt N¢_ D:": 2Z 008

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
DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury,
[R.'_li=i [,]_r
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or
S@J'io_ injury
CAUTION indicates a potentially
hazardous situation which, if not
avoided, _ result in minor or
rnodera'_e i_.
CAUTION used without the safety
alert symbol indicates a potentially
hazardous situation which, if not
avoided, may result in I_r_erty
damage.
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 Iocat Authorized Service Center. always gwe 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
This product is not equipped with a spark arresting muffler. If the
product will be used around flammable materials, or on land covered with
materials such as agricultural crops, forest, brush, grass, or other similar items,
then an approved spark attester must be installed and is legally required in the
state of California. It is aviolation of California statutes section 130050 and/or
sections 4442 and 4443 of the California Public Resources Code, unless the
engine is equipped with aspark arrestor, as defined in section 4442, and
maintained in effective working order. Spark arresters are also required on some
U. S. Forest service land and may also be legally required under other statutes
and ordinances.
This product may contain chemicals known to the state of California to cause
cancer, birth defects, or other reproductive harm. This warning is given in
compliance with California Proposition 65, as detectable amounts of chemicals
subject to proposition 65 may be contained in this product.
READ AND FOLLOW ALL INSTRUCTIONS.
This tool was designed for certain applications PortepCable 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 wrJtten Porter-Cable and we have advised you.
Technical Service Manager
Porter-Cable Corporation
4825 Highway 45 North
RO. Box 2468
Jackson, TN 38302 2468
2 _ NC,

IMPORTANT SAFETY INSTRUCTIONS (cont'd)
SAVE THESE INSTRUCTIONS _\ I
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 i_ I
i
WHAT CAN HAPPEN
GASOLINE AND GASOLINE VAPORS CAN BECOME
IGNITED BY COMING INTO CONTACT WITH HOT
COMPONENTS SUCH AS THE MUFFLER, FROM
ENGINE EXHAUST GASES, OR FROM AN
ELECTRICAL SPARK,
COMBUSTIBLE .MATERIALS WH]CH COME INTO
CONTACT WITFI HOT ENGIN EPARTS CAN BECOME
IGNITED
UNATTENDED OPERATION OF THIS PRODUCT
COULD RESULT IN PERSONAL INJURY OR
PROPERTY DAMAGE.
RISK OF BURSTING
I
HOW TO PREVENT IT
TURN ENGINE OFF AND ALLOW IT TO COOL
BEFORE ADDING FUEL TO THE TANK EQUIP
AREA OF OPERATION WITH A FIRE EXTINGUISHER
CERBEIED TO HANDLE GASOLINE OR FUEL FIRES
ADD FUEL OUTDOORS IN A WELL VENTILATED
AREA MAKE SURE THERE ARE NO SOURCES OF
IGNITION, SUCH AS CIGARETTES NEAR
REFUELING LOCATION
OPERATE COMPRESSOR IN A CLEAN DRY, WELL
VENTILATED AREA A MINIMUM QF FORTY EIGH]
INCHES FROM ANY BUILDING. OBJECT OR WALL
DO NOT OPERATE UNIT INDOORS OR IN ANY
CONFINED AREA.
STORE FUEL IN A SECURE LOCATION AWAY FROM
COMPRESSOR
ALWAYS REMAIN IN ATTENDANCE WITH THE
PRODUCT WHEN IT IS OPERATING.
r
AIR TANK: THE FOLLOWING CONDITIONS COULD LEAD TO A WEAKENING OF THE TANK, AND RESULT
IN A VIOLENT TANK EXPLOSION AND COULD CAUSE PROPERTY DAMAGE OR SERIOUS INJURY.
WHAT CAN HAPPEN
1FAILURE TO PROPERLY DRAIN CONDENSED
WATER FROM THE TANK, CAUSING RUST AND
THINNING OF THE STEEL TANK
2 MODIFICATIONS OR A_IEMPTED REPAIRS
TO THE TANK.
3UNAUTHORIZED MODIFICATIONS TO THE
UNLOADER VANE, SAFETY VALVE, OR ANY
OTHER COMPONENTS WHICH CONTROL
TANK PRESSURE.
4EXCESSIVE VIBRATION CAN WEAKEN THE AIR
TANK AND CAUSE RUPTURE OR EXPLOSION.
EXCESSIVE VIBRATION WILL OCCUR iF THE
COMPRESSOR IS NOT
PROPERLY MOUNTED OR IF THE ENGINE
OPERATES ABOVE RECOMMENDED RPM
ATTACHMENTS & 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 [ EAK REPL_,CE IT IMMEDIATELY WITH
A NEW TANK OR REPLACE THE ENTIRE
COMPRESSOR
NEVER DRILL INTO, WELD, OR MAKE ANY
MODIFICATIONS TO THE TANK OR ITS
AI_ACH MENTS
THE TANK IS DESIGNED TO WITHSTAND SPECIFIC
OPERATING PRESSURES NEVER MAKE
ADJUSTMENTS OR PARTS SUBSTITUTIONS TO
ALTER THE FACTORY SET OPERATING
PRESSURES.
DO NOT REMOVE THE STIFFENER BAR
CONNECTING THE COMPRESSOR PUMP ]O THE
ENGINE EXCEPT TO ADJUST BELT TENSION THEN
SECURELY TIGHTEN THE STIFFENER BAR NUTS
THIS BAR CONTROLS OUTFIT VIBRATION.
FOR ESSEN]IAL 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 RATINGOFAI_ACHMENTS NEVERUSE
COMPRESSOR TO INFLATE SMALL LOW-
PRESSURE OBJECTS SUCH AS CHILDREN'S
TOYS, FOOTBALLS, BASKETBALLS. ETC.
3FNG

IMPORTANT SAFETY INSTRUCTIONS (cont'd)
RISK FROM FLYING OBJECTS >a
WHAT CAN HAPPEN 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
THE COMPRESSED AIR STREAM CAN CAUSE
SOFT TISSUE DAMAGE TO EXPOSED SKIN AND
CAN PROPEL DIRT¸ CHIPS¸ LOOSE PARTICLES
AND SMALL OBJECTS A1 HIGH SPEED¸
RESULTING IN PROPERTY DAMAGE QR PERSONAL
INJURY¸
RISK TO BREATHING
WHAT CAN HAPPEN HOW TO PREVENT IT
BREATHING EXHAUST FUMES FROM ENGINE
WILL CAUSE SERIOUS INJURY OR DEATH.
THE COMPRESSED AIR FROM YOUR
COMPRESSOR IS NOT SAFE FOR BREATHING!
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 HARMFUL VAPORS AND
POISONS
ALWAYS OPERATE AIR COMPRESSOR OUTSIDE
IN A CLEAN, WELL VENTILATED AREA. AVOID
ENCLOSED AREAS SLiCH ,\S GARAGES
BASEMENTS STORAGE SHEDS WHICH LACK A
STEADY EXCHANGE Of AIR KEEP CHILDREN
PETS AND OTHERS A_,AY FROM AREA OF
OPERATION
NEVER INHALE AIR PROM 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 ANIOSH/MSRA APPROVED
RESPIRATOR DESIGNED FOR USE WITH YOUR
SPECIFIC APPLICATION
RISK FROM MOVING PARTS r_
WHAT CAN HAPPEN HOW TO PREVENT IT
THE ENGINE CAN START ACCIDENTALLY IF THE ALWAYS DISCONNECT THE SPARK PLUG AND
FLYWHEEL IS TURNED BY HAND OR MOVED BY BLEED PRESSURE FROM THE TANK BEFORE
PULLING ON THE STARTER ROPE PERFORMING MAINTENANCE.
MOVING PARTS SUCH AS THE PULLEY FLYWHEEL
ANDBE[, CAN CAUSE SERIOUS INJURY, IFTHEY
COME INTO CONTACT WI]H YOU DR YOUR
CLOTHING
ATTEMPTING TO OPERATE COMPRESSOR WITH
DAMAGED OR MISSING PARTS OR ATTEMPTING
TO REPAIR COMPRESSOR WITH PROTECTIVE
SHROUDS REMOVED CAN EXPOSE YOU TO
MOVING PARTS AND (;AN RESULT IN SERIOUS
INJURY.
NEVER OPERATE THE COMPRESSOR WITH
GUARDS OR COVERS WHICH ARE DAMAGED OR
REMQVED
ANY REPAIRS REQUIRED ON IHIS PRODUCT
SHOULD BE PERFORMED BY AUTHORIZED
SERVICE CENTER PERSONNEL.
4 ENG

IMPORTANT SAFETY INSTRUCTIONS (cont'd)
RISK OF BURNS
WHAT CAN HAPPEN
TOUCHING EXPOSED METAL SUCH AS THE
COMPRESSOR HEAD OR OUTLET TUBES OR
CONTACT WITH HOT ENGINE PARTS, SUCH AS
TBE MUFFLER, CAN RESU_IN SERIOUSBURNS.
THE GASOLINE ENGINE, THE ENGINE MUFFLER,
THE COMPRESSOR HEAD AND TUBING BECOME
VERY HOT DURING OPERATION
HOW TO PREVENT IT
NEVER TOUCH ANY EXPOSED METAL PARTS ON
ENGINE OR COMPRESSOR DURING OR
IMMEDIATELY AFTER OPERATION ENGINE AND
COMPRESSOR WILL REMAIN NOT 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
A PORTABLE COMPRESSOR CAN FALL FROM A
TABLE, WORKBENCH OR ROOF CAUSING
DAMAGE TO THE COMPRESSOR AND COULD
RESULT IN SERIOUS INJURY OR DEATH TO THE
OPERATOR OR BYSTANDERS.
HOW TO PREVENT IT
ALWAYS OPERATE COMPRESSOR IN ASTABLE
SECURE POSITION TO PREVENT ACCIDENTAL
MOVEMENT OF THE UNIT NEVER OPERATE
COMPRESSOR ON A ROOF OR OTHER ELEVATED
POSITION. USE ADDITIONAL AIR HOSE TO
REACH HIGH LOCATIONS.
RISK OF PROPERTY DAMAGE WHEN
TRANSPORTING COMPRESSOR
(Fire, Inhalation, Damage
to Vehicle Surfaces)
WHAT CAN HAPPEN
FUEL OR OIL CAN LEAK OR SPILL AND COULD
RESULT IN FIRE OR BREATHING HAZARD,
SERIOUS INJURY OR DEATH CAN RESULT. FUEL
OR OIL LEAKS WILL DAMAGE CARPET, PAINT OR
OTHER SURFACES IN VEHICLES OR TRAILERS
HOW TO PREVENT IT
IF COMPRESSOR IS EQUIPPED WITH A FUEL SHUT-
OFF VALVE, TURN THE VALVE TO THE OFF
POSITION BEFORE TRANSPORTING TO AVOID
FUEL LEAKS. iF COMPRESSOR IS NOT EQUIPPED
WITH A FUEL SHUT-OFF VALVE, DRAIN THE FUEL
FROM TANK BEFORE TRANSPORTING
TRANSPORT FUEL ONLY IN AN OSHA APPROVED
CONTAINER ALWAYS PLACE COMPRESSOR ON A
PROTECTIVE MAT WHEN TRANSPORTING TO
PROTECT AGAINST DAMAGE TO VEHICLE FROM
LEAKS. REMOVE COMPRESSOR FROM VEHICLE
IMMEDIATELY UPON ARRIVAL AT YOUR
DESTINATION.
Gsw*g9 -- 9/22/99
5 ENG

GLOSSARY
CFM: Cubic feet per minut_
SCFM: Standard cubic feet per rninute;a unit of measure of air delivery
PSlG: Pounds per square Jncl_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 (¢)(2)/(M) (2).
Specification/mode/ label is on the side of the tank on units that comply with
California Code.
Unloader Blow-Off Pressure: When the maximum tank pressure is obtained, the
unloader valve will blow off This will cause the conqpressor to exhaust the air to
the atmosphere and not into the tank. This decreases the load on the engine and
allows it to run at a near no load condition.
Unloader Reset Pressure: When the tank pressure drops to a pre determined
point, the unloader valve closes The tank pressure will now increase until it
reaches the unloader blow-oft pressure.
Code Certification: Products that bear one or more of the following marks: UL,
CUL, ETL, CETL, have been evaluated by OSHA certified independent safety
laboratories and meet the applicable Underwriters Laboratories Standards for
Safety.
DUTY CYCLE
Porter-Cable air compressors should be operated eta not more than a 50% duty
cycle This means an air compressor that pumps air more than 50% of one hour is
considered misuse, because the air compressor is undersized for the required air
demand. Maximum compressor pumping time per hour is 30 minutes.
Model No.
SPECIFICATIONS
SCFM @ 90 PSIG
CPL55GH8W
Engine Horsepower 5.5
Bore 2.875"
Stroke 2.0"
Air Tank Capacity (Gallon) 8
Approximate Unloader Reset Pressure 110 PStG
Approximate Unloader Blow-off Pressure 135 PSIG
SCFM @ 40 PSIG 12.0
101
IMPORTANT: See engine operator's manual for engine information.
6 _NG

DESCRIPTION OF OPERATION
Air Compressor Pump (not shown): D
Compresses air into the air tank. E C
Unloader Valve (not shown): When the
maximum tank pressure is obtained, the
unloader valve will exhaust the
compressed air to the atmosphere
(blow-off). When the tank pressure drops
to a pre determined point, the unloader
valve closes and causes the tank
pressure to increase.
Safety Valve (C} Fig. 1: If the unloader Fig. 1
valve does not retease pressure when tank reaches "blow-off" pressure, the safety
valve will protect against high pressure by "popping off" at its factory set pressure
(slightly higher than the pressure switch blow off setting).
Outlet Pressure Gauge (D) Fig. 1: The outlet pressure gauge indicates theail
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 (El Fig. 1: The tank pressure gauge indicates the reserve a_r
pressure in the tank.
Regulator (F} Fig. 1: Controls the air pressure shown on the outlet pressure gauge
Puff the knob out and turn clockwise to increase pressure and counterclockwise to
decrease pressure, When the desired pressure is reached push knob in to lock in
place.
Drain Valve (not shown}: A drain valve is located at the base of each air tank and
is used to drain condensation at the end of each use
Air Intake Filter (not shown}: This filter is designed to clean air coming into the
pump. This filter n3_ust,always be clean and ventilation openings free from
obstructions. See "Maintenance".
Throttle Control (not shown): A throttle control has been rncorporated as an extra
feature. When maximum tank pressure is reached and the unloader valve vents air.
it also activates a throttle control on the engine. This gas saving feature holds the
engine at a factory-set idling speed until air pressure in the air tank drops to reset
pressure. It then reactivates the throttle control and accelerates the engine to full
throttle.

INSTALLATION
_THE WHEEL AND HANDLES DO NOT PROVIDE ADEQUATE
CLEARANCE, STABILITY OR SUPPORT FOR PULLING THE COMPRESSOR UP
AND DOWN STAIRS OR STEPS. THE COMPRESSOR MUST BE LIFTED, OR
PUSHED UP A RAMP.
1. Push rubber handle
grips (L), onto
handle tubes (M).
Seat firmly. Use a
twisting motion to
ease assembly. See
Fig. 2.
2. Position one
handle and grip
assembly into
clamp on left side
of tank assembly,
as shown in Fig. 2.
Align hole in handle
with hole in clamp.
3.
4.
L
O
S
Inser_ bolt (N)
through the hole (in Fig. 2
clamp and handle). Thread nut (O) onto bolt. Using two 1/2" wrenches (not
furnished) tighten nut securely.
Repeat step 2 to assemble remaining handle and grip assembly to the clamp
on the right side of tank assembly.
Using a 9/16" socket wrench (not furnished) remove the four bolts securing the
compressor to the shipping skid.
A. Place spacer (S) on flat side of a rubber foot (R). Place spacer and rubber
foot against compressor frame as shown in Figure 2.
B. Align hole in spacer and rubber foot with one of the smaller holes adjacent to
the holes where shipping skid was attached.
C. Insert one of the 1/4"-20 x 3/4" bolts (P), from the hardware package, and
using a 3/8" socket wrench (not furnished) tighten firmly.
D. Repeat A through C to install the three remain=ng rubber feet.
Location of the Air Compressor
EXHAUST FROM THE GASOLINE ENGINE CONTAINS
DEADLY CARBON MONOXIDE, WHICH IS ODORLESS AND TOXIC.
OPERATE ENGINE ONLY IN WELL-VENTILATED AREAS.
The air compressor must be operated in a clean, dry, and well-ventilated area. The
air compressor's crankcase and head are designed with cooling fins to provide
proper cooling. The fan blades of the compressor, the flywheel, must be kept clear
of obstructions that could interfere with the flow of air through the air intake filter.
Do not install the air compressor in a location where heat is excessive. If the
humidity in the operating area is high, an air filter can be installed on the air outlet
adapter 1o remove excessive moisture. This type air filter is not provided with this
air compressor and must be purchased separately. Closely follow the instructions
packaged with the filter for proper installation.
_Do not allow the air compressor to get wet if it is
installed outdoors.
8 ENG

Lubrication and Oil
Engine
1. Position the unit on a level surface.
2. Remove spark plug wire from spark plug.
3. Remove oil drain plug (A) Fig 3. Dispose of
oi_drain plug.
4 Obtain the drain plug extension (B) Fig. 3,
from the parts bag.
5. Apply thread sealant tape to the threads of
the drain plug extension (B).
NOTE: Each end of the drain plug extension
has different type threads. If drain plug
extension will not turn more than one full turn
by hand, remove and try the other end.
6. Assemble the drain plug extension (B) and
cap (D, found in parts bag) as shown in Fig.
3.
7. Tighten securely.
8. Remove the oil fill plug {C) Fig. 3.
D B
Fig. 3
9. Add engine oil to crankcase of the gasoline engine. Use high quality 10W-30
weight multi-viscosity engine oil. Refer to the engine manufacturer's manual
for quantity of oil required and procedure.
10. Replace the oil fill plug {C) and tighten securely.
1!. Remove gasoline cap from tank and fill the tank with fresh, clean, unleaded
gasoline, regular Grade (87 octane). De net use premium gasoline.
GASOLINE VAPOR IS HIGHLY FLAMMABLE. REFUEL
OUTDOORS PREFERABLY, OR ONLY IN WELL-VENTILATED AREAS.
DO NOT REFUEL OR CHECK GASOLINE LEVEL WHILE THE ENGINE
IS RUNNING. DO NOT STORE, SPILL, OR USE GASOLINE NEAR AN
OPEN FLAME, A SOURCE OF SPARKS (SUCH AS WELDING), OR
NEAR OPERATING ELECTRICAL EQUIPMENT.
12. Replace gasoline cap on tank.
13. Attach spark plug wire to the spark plug on the engine.
Air Compressor
!. Place air compressor on a level surface.
2. Remove the pump oil fil! plug and slowly add compressor oil to the crankcase
of the pump until it is even with the top of the oil fill hole (no lower than 3/8"
from the top at any time). Fill with oil slowly. If oil is added too quickly, it will
overflow and appear to be full.
COMPRESSOR PUMPS ARE SHIPPED WITHOUT OIL. A
SMALL AMOUNT OF OIL MAY BE PRESENT IN THE PUMP UPON
RECEIPT OF THE AIR COMPRESSOR. THIS IS DUE TO TESTING BY
THE MANUFACTURER AND DOES NOT MEAN THAT THE PUMP
CONTAINS OIL. DO NOT ATTEMPT TO OPERATE THIS AIR
COMPRESSOR WITHOUT FIRST ADDING OIL TO THE PUMP'S
CRANKCASE. SERIOUS DAMAGE TO THE PUMP CAN RESULT FROM
EVEN LIMITED OPERATION UNLESS IT IS FILLED WITH OIL AND
BROKEN IN CORRECTLY. BE SURE TO CLOSELY FOLLOW THE
INITIAL PREPARATION FOR USE AND START-UP PROCEDURES.
NOTE
The pump crankcase oil capacity is 16 fluid ounces.
9 EN('_

I_'_11 Multi-viscosity motor oils such as 10W-30 should not be
used in an air compressor. Multi-viscosity oils ieave carbon deposits
on critical components, reducing their performance and shorlening
compressor life. Only use oil designated for use in air compressors.
Castrol Heavy Duty 30 weight oil may be used if compressor oil is not
immediately available.
3. Replace the pump oil fill plug and tighten
NOTE
Drain and refill the compressor crankcase after the first 100 hours of
operation.
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.
I_a pipe line is _Tecessary, Lise p_pe that is the same s_ze as the air tank outlet
P;pillg that is too snlallwillrestrlct the rio,, (>fair If piping _s ovel !00 feet long
use the next larger size Bury underground I_nes below the frost fine and avoid
i;ockets where condensation cam 9lather L_nd freeze Apply pressu_eto hn*._s befofd
underground liiles ale buried to make sure all ppe joHlts are free of leaks
BREAK-IN PROCEDURES
Serious damage may result if the following break-in
instructions are not closely followed.
This procedure is required when:
1 Before the a_r compressor is used for the first time
"_ Wher_ the check valve is replaced
3 When a (:omplete compressor pump IS replaced
The procedure:
1 !o prevent pressurt_ floe building up in the _qirtanks
dtlring this break in pellod you mLrSt open the unit's
unloader valve Place UrTIoader valve ir_ "Open"
position as shown ill Figure 4
?Open the pressure regulator (Refer to F_gure 1 for
location) Pull regulator knob and rotate clockwise
L_ntil it stops
Refer to Figure 50_thegasolineengH_e move the
fuel valve control to the "ON" posibon
,l Move the choke lever to the "Close" pos_hon Fig. 4
f
Fig. 5
:,,it,

NOTE
A warm engine requires less choking than a cold engine.
5 Turn the engine switch to the "ON" position.
The air compressor is top heavy. Make sure the unit is
sition and will not tip before pulling the starter cord of
the engine.
6 Pullthe starter grip lightly until resistance is felt. then pullbriskly NOTE: Do
not allow the starter grip to snap back against the engine, Return it gently to
pr'_vent damage to the starter
7 When the engine starts push the choke control to the "Open" position
8. Make sure the unloader valve is in the "Open" position to prevent tank
pressure buildup (Figure 4)
Serious damage may result to the compressor pump if
the following break-in procedures are not closely followed.
9 Run the air compressor for 30 minutes to seat the rings and lubricate all the
internalsurfaces Make sure there,s no pressure build up in the tank by
observing the reading on the tank pressure gauge
10 Place unloader valve in the "Closed" position as
shown in Figure 6).
!I Close the pressure regulator Rotate the regulator
knob counter clockwise to its built-in stop and push
knob in to lock in place This will allow air to build
pressure in the air tanks
12 When the air tanks are pressurized, the tank pressure
gauge wil! indicate the pressure available in the air
tanks and the gasoline engine will reduce its speed
to idle and keep running The pressurization of the
air tanks will be adjusted automatically by the Fig. 6
settings of the "reset" and "blow off" switches. When the pressure in the air
tank drops to the "reset" value, the gasoline engine will increase its rpm to
operate the compressor and pressurize the tanks. When the pressure in the
air tank mcreasesto the "blow off" value the engine rpm wi!l drop to idle
13 The pressure regulator can now be adjusted to the required pressure for
operating your air tools, usually 90 PSIG
NOTE
Gasoline engine break-in usually takes five hours of normal running,
after which time the engine oil should be changed. Consult the engine
manufacturer's manual for the proper engine break-in running time
and oil change interval for the engine used on your air compressor as
well as other engine maintenance requirements.
14 Turning the gasoline engine off will turn off the air compressor as well
Compressed air will be available from the unit's outlet valve until it is used up
or bled off Consult theenglne marlufacturer'slnanual for the procedure to
safely shut down the gasoline engine

OPERATING PROCEDURES
Daily Start-Up Checklist
Before Starting Unit
Perform the following checks before starting the air compressor.
1. Make sure that nothing is blocking the belt guard, air openings or air filter
inlet.
2. Make sure the unloader valve moves freely and smoothly. Refer to Figures 4
and 6.
3. Check the oil level in the pump and engine, add oil if necessary.
4. Clean or blow off fins or any part of the air compressor that collects dust and
dirt. The air compressor will run cooler and provide longer service.
5. Close the pressure regulator of the air compressor before starting the engine.
At Start-Up
6. Start the engine of the air compressor and allow tank pressure to pump up to
blow off pressure
TOO MUCH AIR PRESSURE CAUSES A HAZARDOUS
RISK OF BURSTING. CLOSELY MONITOR THE AIR PRESSURE
GAUGE OF THE TANK SO THE MAXIMUM PRESSURE LIMIT IS NOT
EXCEEDED AND MONITOR THE SAFETY VALVE TO ENSURE EXCESS
PRESSUREIS DISCHARGED. IF PRESSURE CONTINUES TO BUILD
BEYOND SAFE LIMITS, SHUT THE UNIT DOWN IMMEDIATELY AND
TROUBLESHOOT THE PROBLEM.
7 Check all fittings and piping for air leaks. Even minor leaks can cause the air
compressor to overwork, resulting In premature breakdown or unsatisfactory
performance.
8. Check for any unusual vibration and no=se.
9. Check for oil leaks and correct any leaks found.
t0. Check the pressure ratings of the air tools and accessories being used with
this air compressor before attaching, then adjust the pressure regulator gauge
for that value.
THE AIR COMPRESSOR'S OUTLET PRESSURE MUST
NEVER EXCEED THE MAXIMUM PRESSURE RATING OF THE TOOL
OR ACCESSORY BEING USED. IF A PRESSURE REGULATOR IS NOT
USED, DO NOT USE ACCESSORIES RATED AT LESS THAN 110 PSlG.)
11 Attach air hose and accessory. Your unit is ready for use .
I_/_'_'I'_JL_ll Cornpressed air from the unit contain watermay
condensation and oil mist. Do not spray unfiltered air at an item that
could be damaged by moisture. Some air operated tools or devices
may require filtered air. Read the instructions for the air tool or device.
Shutting Down
12. Turn off engine
13. Shut off the outlet valve or air pressure regulator.
14. Remove the air tool or accessory.
15. Open outlet valve or pressure regulator and allow air to slowly bleed from the
tank Close the outlet valve or regulator when the tank pressure is
approximately 20 PSIG
12 EN(

DRAIN AIR TANKS DAILY. WATER WILL CONDENSE IN
AIR TANKS. IF NOT DRAINED, WATER WILL CORRODE AND WEAKEN
THE AIR TANKS CAUSING A RISK OF TANK RUPTURE.
16. With tank pressure at approximately 20 PSIG, open the drain valves and allow
moisture to drain. NOTE
If drain cock is clogged, release all air pressure. The drain cock can
then be removed, cleaned, and reinstalled.
17. After the water has been drained, close the drain cocks. The air compressor
can now be stored.
MAINTENANCE
DURING MAINTENANCE, YOU COULD BE EXPOSED TO
COMPRESSED AIR OR MOVING PARTS. PERSONAL INJURIES CAN
OCCUR. BEFORE DOING ANY MAINTENANCE OR REPAIR,
DISCONNECT THE SPARK PLUG WIRE TO PREVENT ACCIDENTAL
STARTING OF THE ENGINE, AND RELIEVE AIR TANK PRESSURE.
NEVER OPERATE THE COMPRESSOR WITH THE BELT GUARD
REMOVED.
To ensure efficient operation and longer life of the air compressor, a routine
maintenance schedule should be prepared and followed. The following routine
maintenance schedule is geared to an air compressor in a normal working
environment operating on a daily basis. If necessary, the schedule should be
modified to suit the conditions under which your air compressor is used. The
modifications will depend upon the hours of operation and the working
environment. An air compressor in an extremely dirty and/or hostile environment
will require a greater frequency of all maintenance checks. Lubricate compressor
motor (if required) according to manufacturer's instructions, which are attached to
your Engine Owners Manual.
Before each use:
1. Check oil levels. Add if necessary.
2. Manually check all safety valves to make sure they are operating properly.
3. Inspect for oil leaks and repair any leaks found.
4. Inspect air filter, replace if necessary.
Every 40 Hours of Operation:
1. Clean and inspect the air intake filter; replace if necessary.
2. Inspect condition of drive belt; replace if necessary.
Every 100 Hours of Operation:
1. Drain and refill compressor crankcase with 16 fluid ounces (473.2 ml) of clean
compressor oil or Castrol Heavy Duty 30 weight.
2. Increase frequency of oil changes if humidity or operating conditions are
extreme.
Every 160 Hours of Operation:
1. Check drive belt tension; adjust if necessary. (Refer to "Service Instructions" in
this manual.)
2 Inspect air lines and fittings for leaks; correct as necessary.
3. Check the alignment of the motor pulley to the flywheel. If necessary, align to
within 1/!6" or] centerline.
13 ENG

Each Year of Operation or ff a Problem is Suspected:
If you have properly serwced you_ air compressor, oil Levels are (oHect, belts ar(
aligned, and the unit {s not functioning p_operly, check the condition of tile air
compressor pump intake and e×haust valw;s Refer to the "Service instructions
section of this manual Replace any valves in the pump that are damaged o_ worn
out
If you feel your air compressol sti!l does not function properly after checking or
replacing the intake and exhaust valves contact your nearest Authorized Service
Center
SERVICE INSTRUCTIONS
Air Compressor Unit
A clean air compressor and ,_mglne run cooler and provide longer serwce Cleats or
blow off fins and any other parts of the air compressor and engine that collect dust
or dirt. Do not place tags. containers or other material on or against the ventilation
openings in the belt guard. Adequate ventilation is necessary to maintain proper a_r
compressor operating temperature
Safety Valve-Inspection and Replacement
IF THE SAFETY VALVE DOES NOT WORK PROPERLY,
OVER-PRESSURIZATION CAN OCCUR AND CAUSE AIR TANK
RUPTURE OR EXPLOSION. DAILY PULL THE RING ON THE SAFETY
VALVE AND MAKE SURE IT OPERATES FREELY. IF THE VALVE IS
STUCK OR DOES NOT OPERATE SMOOTHLY, IT MUST BE REPLACED
WITH THE SAME TYPE OF VALVE HAVING AN IDENTICAL PRESSURE
RATING.
To Remove Safety Valve:
1. Make sure the air compressor unit is off and disconnect the spark plug wire
2. Open the outlet valve and allow all air to bleed from the tank Monitor tank
pressure gauge as tank is emptied.
3. When tank is empty, remove safety
valve (A) from manifold. Refer to A
Figure 7
To Install New Safety Valve:
1 Verify new safety valve is the correct
pressure rating for your a_r
compresson
2 Verify threads for safety valve in
manifold are clean
3 Apply thread sealant to the threads
of new safety valve Fig. 7
4 Install new valve and hand tighten.
5 Tighten nut to secure safety valve to manifold Do not overtighten.
6 Reconnect spark plug wire to engine
7 Perform the Daily Start Up Checklist
Belt - Replacement and Adjustment
SERIOUS INJURY OR DAMAGE MAY OCCUR IF PARTS
OF THE BODY OR LOOSE ITEMS GET CAUGHT IN MOVING PARTS.
NEVER OPERATE THE UNIT WITH THE BELT GUARD REMOVED. THE
BELT GUARD SHOULD BE REMOVED ONLY WHEN THE AIR
COMPRESSOR IS TURNED OFF AND SPARK PLUG WIRE IS
DISCONNECTED.

BeltGuard-Removal
1 Disconnect the spark plug w_re on
the engine and release all air tank
pressure
2 (Refer to Figure 8) Remove the six
screws (A) from the belt guard The
front of the belt guard can now be
removed.
Belt - Replacement
1 Disconnect the spark plug wire on
the engine and release all air tank
pressure.
2 Remove the front of the belt guard
as previously described.
3 Mark eng{ne position on saddle
4. Loosen stiffener bracket screw on engine.
5 (Refer to Figure 9) Being careful not to
remove the stiffener plate under the saddle,
loosen the four engine mounting bolts (C)
6. Slide engine toward pump to remove
tension from the belt and then remove the
old belt.
7 Install the new belt over the pulleys.
NOTE
8.
Fig. 8
The belt must be centered over the
grooves on the engine pulley and Fig. 9
flywheel.
Slide the engine back into its regular position. Line the engine up with the mark
made earlier on saddle.
Belt Tension - Adjustment
1 Slide the engine back into its
regular position. Line the
engtne up with the mark made
earlier on saddle
2. Hold belt tension and securely
tighten two engine mounting
bolts.
3 Measure correct belt tension
Proper tension is achieved
when a three (3) pound weight
or equivalent finger pressure
applied midway between the
motor pulley and compressor
flywheel causes a !/4"
Fig. 10
deflection of the belt Refer to Figure 10
4. When proper belt tension is achieved, tighten the remaining engqne mounting
bolts.
5 Tighten stiffener bracket screw. NOTE
Once the engine pulley has been moved from its factory set location,
the grooves of the flywheel and pulley must be aligned to within 1/16"
to prevent excessive belt wear. Verify the alignment by performing the
following Pulley and Flywheel - Alignment.

Pulley and Flywheel - Alignment
The air compressor flywheel and engine pulley must be in-line (in the same plane)
within 1/16" to assure belt retention within flywheel belt grooves. To check
alignment, perform the following steps:
Disconnect the spark plug wire on the engine and release all air tank pressure.
1.
2.
3.
4.
Remove belt guard.
Place a straightedge
against the outside of the
flywheel and the engine
drive pulley. Refer to
Figure 11 as required.
Measure the distance
between the edge of the
belt and the straightedge
at points A1 and A2 in
Figure 11. The difference
V-BELT ENGINE PULLEY
1 ,,, I
/
AI=A2(MEASURED) STRAIGHT
BI=92(VISUAL) EDGE
Fig. 11
between measurements should be no more than 1/16".
5. If the difference is greater or less than 1/16", loosen the setscrew holding the
engine drive pulley to the shaft and adjust the pulley's position on the shaft
until the A1 and A2 measurements are within 1/16" of each other.
6. Tighten the engine drive pulley setscrew to 70 80 in.qbs.
7. Visually inspect the engine drive pulby to verify that it is perpendicular to the
drive motor shaft. Points B1 and B2 of Figure 10 should appear to be
equal. If they are not, loosen the setscrew of the engine drive pulley and
equalize B1 and B2, using care not to disturb the belt alignment performed _n
step 2.
8. Retighten the engine drive pulley setscrew to 70-80 in.-Ibs.
9. Reinstall belt guard.
10. Reconnect spark plug wire to spark plug on engine.
Compressor Pump
Air Intake Filter--Inspection and Replacement
Keep the air filter clean at all times. Do not operate the
air compressor with the air filter removed.
A dirty air filter will not allow the compressor pump to operate at full capacity.
Before you use the compressor pump, check the air filter to be sure it is clean and
in place (Refer to (B), Figure 8). If it is dirty, replace it with a new filter.
Checking and Changing
Overfilling with oil will cause premature compressor
pump failure. Do not overfill.
Check oil level in the crankcase before each use. Remove the oil fill pluq. The
oil level should be even with the top of the fill hole and must not be lower than
3/8" from the top (6 threads) at any time. It is recommended that the oil be
changed after every 100 hours of operation. To drain the oil, remove the oil drain
plug and collect the oil in a suitable container. Be sure to replace the plug securely
before adding new oil. Use compressor oil or Castrol Heavy Duty 30 weight oil.
Crankcase oil capacity is 16 fluid ounces (473.2 ml).
16 ENG

Servicing Compressor Intake and Exhaust Valves
The air compressor's intake and exhaust valves as well as the valve plates and
cylinder head, witl, over a period of time, accumulate a residue of carbon-like
material on their surfaces. The material will decrease the efficiency of the pump.
These components should be inspected whenever a problem is suspected and they
should be cleaned or replaced with new parfs. Refer to the Parts Manual, if
required. Use the following procedure to inspect these components.
1. Disconnect the spark plug wire on the engine and retieve all air tank pressure.
2 Disconnect the pressure release and outlet tines from the air compressor.
3 Remove the hardware securing the cylinder head, then remove the cylinder
head and valve plate.
MANY SOLVENTS ARE HIGHLY FLAMMABLE AND A
HEALTH HAZARD IF INHALED. ALWAYS OBSERVE THE SOLVENT
MANUFACTURER'S SAFETY INSTRUCTIONS AND WARNINGS.
4 Clean carbon deposits in head cavities and valve plates with lacquer thinner or
other suitable solvent.
5. Clean the intake and exhaust valves with lacquer thinner or other suitable
solvent. Inspect valves; replace if necessary.
NOTE
Do not use gasket cement on any gasket surface as this may clog
pump valve cavities and air flow areas.
6. Reinstall valve plate and use new gaskets
7. _nstall the cylinder head. Snug mounting screws and studs tight, then torque
to 25 to 30 ft,-Ibs, starting at the center and working toward the outside
8. Reconnect the pressure release and outlet lines to the compressor pump.
Engine
Read the engine manufacturer's "Operating and Maintenance Instructions" that
were provided with your air compressor.
17 EN{;

STORAGE
Before you store the air compressor, make sure you do the following:
1 Review the "Maintenance" section on the preceding pages and perform
scheduled maintenance as necessary.
2. Review the "Engine Manufacture's Operating and Maintenance Instructions".
3. Turn the regulator counterclockwise and set the outlet pressure to zero.
4. Remove the air tool or accessory
5 Pull ring on safety valve allowing air to bleed from the tank until tank pressure
_sapproximately 20 psi. Release safety valve ring.
6 Drain water from air tank by opening drain cock valve on bottom of tank
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
If drain cock valve is plugged, release all air pressure The varve can then
be removed, cleaned, then reinstalled.
8. Protect the air hose from damage (such as being stepped on or run over).
Store the air compressor in a clean and dry location
18 EN/I

TROUBLESHOOTING GUIDE
PERFORMING TROUBLESHOOTING OR REPAIRS CAN
EXPOSE MOVING PARTS OR COMPRESSED AIR SOURCES.
PERSONAL INJURY MAY OCCUR. PRIOR TO ATTEMPTING ANY
TROUBLESHOOTING OR REPAIRS, THE ENGINE SPARK PLUG WIRE
SHOULD BE REMOVED. NEVER OPERATE THE UNIT WITH THE BELT
GUARD REMOVED. THE BELT GUARD SHOULD BE REMOVED ONLY
WHEN THE SPARK PLUG WIRE IS REMOVED.
PROBLEM CAUSE CORRECTION
Excessive tank Unloader valve does not Unloader valve must be replaced.
pressure - safety release pressure when tank
valve pops off. reaches "blow-off" pressure.
Air leaks at fittings Tube fittings are not tight Tighten fittings where air can be
enough, heard escaping. Check fittings with
soapy water solution. DO NOT
OVER-TIGHTEN.
Continuous air leak Defective unloader valve. Turn off engine, move unloader
at unloader valve valve to the open position (Figure
4), If air leaks out of tank through
unloader valve, replace unloader
valve. DO NOT OVER-TIGTHEN.
Air leaks in air tank or Damaged air tank.
at air tank welds.
Air leaks between
head and valve
plate.
Pressure reading on
the regulated
pressure gauge
drops when an
accessory is used.
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.
Leaking o-ring. Torque head screws to 8 ft.-Ibs. If
this does not stop leak, replace o-
ring
It is normal for "some"
_ressure drop to occur. If there is an excessive amount of pressure drop when the accessory
is used, adjust the regulator
following the instructions on page
7.
NOTE: Adjust the regulated
pressure under flow conditions
(while accessory is being used).
19 ENG

CAUSE
The fuel valve control is in the
"OFF" position
The gasoline tank is empty
The choke is not set properly
PROBLEM
Engine will not run.
NOTE:
Refer to the engine
mallutacturer's
Marqual for an
Authorized Service
Dealer for warranty
repairs.
Air leak from safety
valve
Knocking noise
Improper fuel mixture
Air tank pressure is too high
Possible defectin safety valve
Loose puUey
Low oil level Cpump or engH_e)
Loose flywheel.
Loose pump or engine
mounting bolts
Loose belt or belt too tight
Carbon build-up
CORRECTION
Move the fuel valve control switch
to the "ON" position
Fill the tank with gas.
Re set the choke Remember, a
warm engine requires less choking
than a cold engine
Ad}ust the fuel mixture
Open the outlet valve and reduce
tank pressure to less than 40 PSIG
Operate safety valve rl!anLJallyby
pulling on nng, If valve still leaks, it
should be replaced
Retighten pulley set screw
Maintain prescribed oil level Add
oi!
Torque bolt 15-20 ft -Ibs
Check bolts, Torque as required
15-20 ft -Ibs.)
Adjust belt tension. Tension belt per
instructions under "Belt Tension-
Adjustments" section of this
manual.
Remove the head and valve plate.
Clean the valve plate and the top of
the piston. (Be sure carbon does
not fall into the cylinden)
Reassemble using new gaskets and
torque bolts 25 to3O ft Ibs.
20 ENG