Porter-Cable CPL55GH8W User manual

Part No. D26998-031-1
Oillube
Compressor
Instruction
manual
To learn more about Porter-Cable
visit our website at:
http://www.porter-cable.com
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.
ESPAÑOL: PÁGINA 27
FRANÇAISE: PAGE 53
IMPORTANT
Please make certain that the person who is to use this
equipment carefully reads and understands these
instructions before starting operations.
PROFESSIONAL POWER TOOLS
Copyright © 2003 PORTER-CABLE Corporation
MODEL
CPL55GH8W

2-ENG
D26998
SAFETY GUIDELINES - DEFINITIONS
Indicates an immi-
nently hazardous sit-
uation which, if not avoided, will
result in death or serious injury.
Indicates a potential-
ly hazardous situa-
tion which, if not avoided, could
result in death or serious injury.
Indicates a potential-
ly hazardous situa-
tion which, if not avoided, may
result in minor or moderate injury.
Used without the
safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may
result in property damage.
This manual contains information that is important for you to know and under-
stand. This information 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 symbols.
IMPORTANT SAFETY INSTRUCTIONS
Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities contains chemicals
known (to the State of California) to cause cancer, birth defects or other repro-
ductive harm. Some example of these chemicals are:
●lead from lead-based paints
●crystalline silica from bricks and cement and other masonry products
●arsenic and chromium from chemically-treated lumber
Your risk from these exposures varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals: work in a well venti-
lated area, and work with approved safety equipment, always wear
MSHA/NIOSH approved, properly fitting face mask or respirator when using
such tools.
When using air tools, basic safety precautions should always be followed to
reduce the risk of of personal injury.
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 arrester must be installed and is
legally required in the state of California. It is a violation of California statutes
section 130050 and/or sections 4442 and 4443 of the California Public
Resources Code, unless the engine is equipped with a spark 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.

3-ENG D26998
IMPORTANT SAFETY INSTRUCTIONS
Save these instructions
Improper operation or maintenance of this product could result in serious injury and
property damage. Read and understand all warnings and operation instructions before
using this equipment.
HAZARD
WARNING: Risk of explosion or fire
How To Prevent It
What Could 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 which come into
contact with hot engine parts can
become ignited.
Unattended operation of this product
could result in personal injury or prop-
erty damage. To reduce the risk of fire,
do not allow the compressor to operate
unattended.
Turn engine off and allow it to cool
before adding fuel to the tank. Equip
area of operation with a fire extinguisher
certified 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 of forty-eight
inches from any building, object or wall.
Do not operate unit indoors or in any
confined area.
Operate compressor in an open area
away from dry brush, weeds or other
combustible materials.
Store fuel in a secure location away from
compressor.
Always remain in attendance with the
product when it is operating.

4-ENG
D26998
WARNING: Risk of Bursting
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.
How To Prevent It
What Could Happen
HAZARD
Drain tank daily or after each use. If
tank develops a leak, replace it immedi-
ately with a new tank or replace the entire
compressor.
1. Failure to properly drain condensed
water from tank, causing rust and
thinning of the steel tank.
2. Modifications or attempted repairs
to the tank. Never drill into, weld, or make any modi-
fications to the tank or its attachments.
Never attempt to repair a damaged or
leaking tank. Replace with a new tank.
4. Excessive vibration can weaken
the air tank and cause rupture or
explosion. Excessive vibration will
occur if the compressor is not
properly mounted or if engine oper-
ates above recommended RPM.
The tank is designed to withstand specific
operating pressures. Never make adjust-
ments 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 (if not
equipped) of your compressor. Follow the
equipment manufacturers recommendation
and never exceed the maximum allowable
pressure rating of attachments. Never use
compressor to inflate small low pressure
objects such as children’s toys, footballs,
basketballs, etc.
ATTACHMENTS & ACCESSORIES:
Exceeding the pressure rating of air
tools, spray guns, air operated acces-
sories, tires, and other inflatables can
cause them to explode or fly apart, and
could result in serious injury.
3. Unauthorized modifications to the
unloader valve, safety valve, or any
other components which control
tank pressure.
Do not remove the stiffener bar con-
necting the compressor pump to the
engine, except to adjust belt tension,
Then securely tighten the stiffener bar
nuts. This bar controls unit vibration.

5-ENG D26998
HOW TO PREVENT IT
WHAT CAN HAPPEN
WARNING: Risk to Breathing
HAZARD
The compressed air directly from your
compressor is not safe for breathing.
The air stream may contain carbon
monoxide, toxic vapors, or solid parti-
cles from the tank. Breathing these cont-
aminant's can cause serious injury or
death.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides,
weed killers, may contain harmful vapors
and poisons.
Air obtained directly from the compressor
should never be used to supply air for
human consumption. In order to use air
produced by this compressor for breath-
ing, suitable filters and in-line safety
equipment must be properly installed.
In-line filters and safety equipment used
in conjunction with the compressor must
be capable of treating air to all applica-
ble local and federal codes prior to
human consumption.
Work in an area with good cross venti-
lation. Read and follow the safety
instructions provided on the label or
safety data sheets for the materials you
are spraying. Use a NIOSH/ MSHA
approved respirator designed for use
with your specific application.
WARNING: Risk from Flying Objects
HOW TO PREVENT IT
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, result-
ing in property damage or personal injury.
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.
HAZARD
Breathing exhaust fumes from engines
will cause serious injury or death.
Always operate air compressor outside
in a clean, well ventilated area. Avoid
enclosed areas such as garages, base-
ments, storage sheds, which lack a steady
exchange or air. Keep children, pets and
others away from area of operation.

6-ENG
D26998
HOW TO PREVENT IT
WHAT CAN HAPPEN
WARNING: Risk of Burns
Touching exposed metal such as the
compressor head, engine head, exhaust
or outlet tubes, can result in serious
burns.
Never touch any exposed metal parts
on compressor during or immediately
after 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.
HOW TO PREVENT IT
WHAT CAN HAPPEN
WARNING: Risk from Moving Parts
Never operate the compressor with
guards or covers which are damaged or
removed.
Moving parts such as the pulley, flywheel,
and belt can cause serious injury if they
come into contact with you or your cloth-
ing.
Any repairs required on this product
should be performed by authorized
service center personnel.
Attempting to operate compressor with
damaged or missing parts or attempting
to repair compressor with protective
shrouds removed can expose you to mov-
ing parts and can result in serious injury.
Always disconnect the spark plug and
bleed pressure from the tank before
performing maintenance.
The engine can start accidentally if the
flywheel is turned by hand or moved by
pulling on the starter rope.
HOW TO PREVENT IT
WHAT CAN HAPPEN
WARNING: Risking of Falling
A portable compressor can fall from a
table, workbench or proof causing dam-
age to the compressor and could result
in serious injury or death to the opera-
tor.
Always operate compressor in a stable
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.
HAZARD
HAZARD
HAZARD

7-ENG D26998
HOW TO PREVENT IT
WHAT CAN HAPPEN
WARNING: Risk of Unsafe Operation
Review and understand all instructions
and warnings in this manual.
Become familiar with the operation and
controls of the air compressor.
Keep operating area clear of all persons,
pets, and obstacles.
Keep children away from the air compres-
sor at all times.
Do not operate the product when
fatigued or under the influence of alco-
hol or drugs. Stay alert at all times.
Never defeat the safety features of this
product.
Equip area of operation with a fire extin-
guisher.
Do not operate machine with missing,
broken, or unauthorized parts.
Unsafe operation of your air compressor
could lead to serious injury or death to
you or others.
HOW TO PREVENT IT
WHAT CAN HAPPEN
Oil can leak or spill and could result in
fire or breathing hazard; serious injury or
death can result. Oil leaks will damage
carpet, paint or other surfaces in vehicles
or trailers.
Always place compressor on a protec-
tive mat when transporting to protect
against damage to vehicle from leaks.
Remove compressor from vehicle immedi-
ately upon arrival at your destination.
Never lie compressor on its side.
(Fire, Inhalation, Damage to Vehicle Surfaces)
WARNING: Risk of Serious Injury or Property Damage when
Transporting Compressor
SPECIFICATIONS
Model No. CPL55GH8W
Engine Horsepower 5.5
Bore 2.875"
Stroke 2.0”
Air Tank Capacity (Gallon) 8
Approximate Unloader Reset Pressure 110 PSIG
Approximate Unloader Blow-off Pressure 135 PSIG
SCFM @ 40 PSIG 12.0
SCFM @ 90 PSIG 10.1
IMPORTANT: See engine operator’s manual for engine information.
HAZARD
HAZARD

8-ENG
D26998
GLOSSARY
Become familiar with these terms before operating the unit.
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per minute; a unit of measure of air delivery.
PSIG: Pounds per square inch gauge; a unit of measure of 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.
California Code: Unit may comply with California Code 462 (l) (2)/(M) (2).
Specification/model label is on the side of the tank on units that comply with
California Code.
Unloader Blow-Off Pressure: All models are continuous running units con-
trolled by tank pressure. When the maximum tank pressure is obtained, the
unloader valve will blow-off. This will cause the compressor to exhaust the air
to the atmosphere and not 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 predetermined
point, the unloader valve closes. The tank pressure will now increase until it
reaches the unloader blow-off pressure.
ASSEMBLY
Unpacking
1. Remove unit from carton and discard all packaging. NOTE: Save all parts
bags.
The wheels and handle do not provide adequate clear-
ance, stability or support for pulling the unit up and down
stairs or steps. The unit must be lifted, or pushed up a ramp.
Installing HandleDo not use the engine gas tank as a support for lifting the
air compressor.
1. Push rubber handle grips (L), onto handle tubes (M). Seat firmly. Use a
twisting motion to ease assembly. See Figure.
R
P
S
N
O
M
L
Accessories for this unit are available at the store the unit was purchased.
ACCESSORIES

9-ENG D26998
2. Position one handle and grip assembly into clamp on left side of tank
assembly, as shown in Figure. Align hole in handle with hole in clamp. Insert
bolt (N) through the hole (in clamp and handle). Thread nut (O) onto bolt.
Using two 1/2" wrenches (not furnished) tighten nut securely.
3. Repeat step 2 to assemble remaining handle and grip assembly to the
clamp on the right side of tank assembly.
4. 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 rub-
ber foot against compressor frame as shown in Figure.
B. Align hole in spacer and rubber foot with one of the smaller holes adja-
cent 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 remaining rubber feet.
Lubrication and Oil
Engine Drain tank to release air pressure before removing the oil
fill cap or oil drain plug.
1. The engine was filled WITH oil at the manufacturer. Check engine oil level
before operating unit. If necessary, fill engine to the appropriate level with
recommended oil, see engine manual supplied by engine manufacturer for
correct procedure.
2. Add fuel to engine. See engine manual supplied by engine manufacturer for
correct procedure.
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.
Air Compressor
The air compressor pump was filled WITH oil at the manufacturer. Check air
compressor pump oil level before operating unit. If necessary, fill pump to the
appropriate level with approved compressor oil, see the Maintenance section of
this manual for details.

10-ENG
D26998
INSTALLATION
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 pro-
vide 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 to 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.
Piping
Plastic or PVC pipe is not designed for use with com-
pressed air. Regardless of its indicated pressure rating,
plastic pipe can burst from air pressure. use only metal pipe for air distri-
bution.
If a pipe line is necessary, use pipe that is the same size as the air tank 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 to lines
before underground lines are buried to make sure all pipe joints are free of leaks.

11-ENG D26998
Description of Operation
Become familiar with these controls before operating the unit.
Air Compressor Pump (not
shown): Compresses air into the
air tank.
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-deter-
mined point, the unloader valve
closes and causes the tank pres-
sure to increase.
Safety Valve (C): If the unloader valve does not release 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): The outlet pressure gauge indicates the air pres-
sure 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): The tank pressure gauge indicates the reserve air
pressure in the tank.
Regulator (F): Controls the air pressure shown on the outlet pressure gauge.
Pull 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 must always be clean and ventilation openings free from ob-
structions. See "Maintenance".
Throttle Control (not shown): A throttle control has been incorporated 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 fea-
ture 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 acceler-
ates the engine to full throttle.
OPERATION
Know Your Air Compressor
READ THIS OWNER’S MANUAL AND SAFETY RULES BEFORE OPERATING
YOUR UNIT. Compare the illustrations with your unit to familiarize yourself with
the location of various controls and adjustments. Save this manual for future
reference.
F
E
DC

12-ENG
D26998
How to Use Your Unit
How to Stop:
1. See the engine manufacturer's manual for the procedure to safely shut
down the gasoline engine. Turning the gasoline engine off will turn off the air
compressor as well.
Before First Start-up
Break-in Procedure
Serious damage may result if the following break-in
instructions are not closely followed.
This procedure is required when:
1. Before the air compressor is used for the first time.
2. When the unloader valve is replaced.
3. When a complete compressor pump is replaced.
The procedure:
1. To prevent pressure from building up in the air tanks during this break-in
period, you must open the unit's unloader valve. Place unloader valve in
“Open” position as shown.
2. Open the pressure regulator. Pull regulator
knob and rotate clockwise until it stops.
3. Start engine. See engine manual supplied by
engine manufacturer for correct procedure.
The air compressor is top
heavy. Make sure the unit is in
a stable position and will not tip before pulling
the starter cord of the engine.
4. Make sure the unloader valve is in the “Open” position to prevent tank
pressure buildup.
5. Run the air compressor for 30 minutes to seat the rings and lubricate all
the internal surfaces. Make sure there is no pressure build up in the tank by
observing the reading on the tank pressure gauge.
6. Place unloader valve in the “Closed” position as shown.
7. 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.
NOTE: When the air tank is pressurized, the tank pres-
sure gauge will indicate the pressure available in the air
tank and the gasoline engine will reduce its speed to
idle and keep running. The pressurization of the air tank
will be adjusted automatically by the "reset" and "blow
off" setting of the unloader valve. 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 increases to the "blow off" value, the engine rpm will drop to idle.
NOTE: 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.
Open
Closed

13-ENG D26998
8. Compressed air will be available from the unit's outlet valve until it is used
up or bled off. The compressor is now ready for use.
Before each start-up
Perform the following checks before starting the air compressor.
1. Make sure nothing is blocking the belt guard, air openings, or air filter inlet.
2. Make sure the unloader valve moves freely and smoothly.
3. Check the oil level in the pump and engine, add oil if necessary.
Temperature of muffler and near by areas my exceed
150°F (65°C) avoid these areas.
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. Open the unloader valve of the air compressor before starting the engine.
To start-up
6. Start the engine (see engine manual supplied by engine manufacturer for
correct procedure) and close unloader to allow tank pressure to pump up to
blow-off pressure.
Unit is top heavy. Make sure the compressor is stable and
will not tip before pulling the starting cord.
Too much air pressure causes a hazardous risk of burst-
ing. 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 pressure is 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 unsatis-
factory performance.
8. Check for any unusual vibration and noise.
9. Check for oil leaks and correct any leaks found.
10. Check the pressure ratings of the air tools and accessories being used with
this air compressor before attaching, then adjust the shut-off valve 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 psi.
11. Attach air hose and accessory. Your unit is ready for use.
Compressed air from the unit may contain water conden-
sation 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. Close the pressure regulator.
14. Remove the air tool or accessory.
15. Open pressure regulator and allow air to slowly bleed from the tank. Close
the regulator when the tank pressure is approximately 20 PSIG.

Drain air tank daily. Water will condense in air tank. If not
drained, water will corrode and weaken the air tank caus-
ing 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.
14-ENG
D26998

15-ENG D26998
MAINTENANCE
Customer Responsibilities
Daily or
after
each
use
Before
each
use
●●●
●1
Every
8
hours
Every
40
hours
Every
100
hours
Yearly
Every
160
hours
●
●1
1- more frequent in dusty or humid conditions
Check Safety Valve
Drain Tank
Oil Leaks
Check Pump Oil
Change Pump Oil
Air Filter
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, and relieve air tank pressure. Never operate the com-
pressor with the belt guard removed.
●
●
●
●
Drive Belt -Condition
Motor Pulley/Flywheel alignment
Air compressor pump intake
and exhaust valves
Unusual Noise and/or Vibration
Consult the Engine Owners Manual for the manufacturer's recommendations
for any and all engine maintenance.
Inspect air lines and fittings
for leaks
●
To ensure efficient operation and longer life of the air compressor outfit, a rou-
tine maintenance schedule should be prepared and followed. The following
routine maintenance schedule is geared to an outfit in a normal working envi-
ronment operating on a daily basis. If necessary, the schedule should be modi-
fied to suit the conditions under which your compressor is used. The modifica-
tions will depend upon the hours of operation and the working environment.
Compressor units in an extremely dirty and/or hostile environment will require a
greater frequency of all maintenance checks.
NOTE: See "Operation"section for the location of controls.
To Check Safety Valve
If the safety valve does not work properly, over-pressuriza-
tion may occur, causing air tank rupture or an explosion.
1. Before starting compressor, pull the ring on the safety valve to make sure
that the safety valve operates freely. If the valve is stuck or does not oper-
ate smoothly, it must be replaced with the same type of valve.

16-ENG
D26998
Oil
Drain tank to release air pressure before removing the oil
fill cap or oil drain plug.
Checking
1. Remove the oil fill plug (A). The oil level should be even
with the top of the fill hole and no lower than 6 threads
from the top of fill hole.
2. If needed, slowly add oil until it reaches the top of fill hole.
NOTE: Use an oil specifically formulated for use in an air com-
pressor, such as Sears 9-16426 air compressor oil.
Changing
1. Remove the oil fill plug (A).
2. Remove the oil drain plug (B) and drain oil into a suitable container.
3. Replace the oil drain plug (B) and tighten securely
4. Slowly fill crankcase to the top of the fill hole. Crankcase capacity is 16
fluid ounces (473.2 ml).
Overfilling with oil will cause premature compressor fail-
ure. Do not overfill.
5. Replace oil fill plug (A) and tighten securely.
A
B
To Drain Tank
1. Turn off engine.
2. Remove the air tool or accessory.
3. Pull ring on safety valve allowing air to bleed from the tank until tank pres-
sure is approximately 20 psi. Release safety valve ring.
4. Drain water from air tank by opening drain valve (counter-clockwise) 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.
5. After the water has been drained, close the drain valve (clockwise). The air
compressor can now be stored.
NOTE: If drain valve is plugged, release all air pressure. The valve can then be
removed, cleaned, then reinstalled.

17-ENG D26998
Air Filter - Inspection and Replacement
Hot surfaces. Risk of burn. Compressor heads are
exposed when filter cover is removed. Allow compressor
to cool prior to servicing.
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 using the compressor pump, check the air filter to make
sure it is clean and in place.
If it is dirty, replace it with a new filter.
1. Remove the air filter cover.
2. Remove the air filter from filter cover.
IMPORTANT: Do not operate the compressor with the air filter
removed.
3. Place new air filter into filter cover. Refer to the "Repair Parts" for the cor-
rect part number.
4. Replace air filter cover and lock into place.
Air Compressor Pump Intake and Exhaust Valves
Once a year have a Trained Service Technician check the air compressor pump
intake and exhaust valves.

18-ENG
D26998
SERVICE AND ADJUSTMENTS
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE PER-
FORMED BY TRAINED SERVICE TECHNICIAN.
Before servicing:
• Stop engine.
• Bleed tank of pressure.
• Allow the air compressor to cool.
Safety Valve-Inspection and Replacement
If the safety valve does not work properly, over-pressuriza-
tion 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 Figure.
To Install New Safety Valve:
1. Verify new safety valve is the
correct pressure rating for your air compressor.
2. Verify threads for safety valve in manifold are clean.
3. Apply thread sealant to the threads of new safety valve.
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.
A

19-ENG D26998
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 the spark plug wire is disconnected.
Belt Guard – Removal
1. Disconnect the spark plug wire on the engine and release all air tank pres-
sure.
2. 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 engine position on sad-
dle.
4. Loosen stiffener bracket screw on
engine.
5. Being careful not to remove the stiffen-
er plate under the saddle, loosen the
six 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: The belt must be centered over
the grooves on the engine pulley and flywheel.
8. 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 engine up with the
mark made earlier on saddle.
2. Hold belt tension and secure-
ly tighten two engine mount-
ing 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 1/4" deflection of
the belt. Refer to Figure 10.
B
3 Pound Force
At Midpoint
1/4 Inch
Deflection
A
C

20-ENG
D26998
4. When proper belt tension is achieved, tighten the remaining engine mount-
ing bolts.
5. Tighten stiffener bracket screw.
NOTE: Once the engine pulley has been moved from its factory set loca-
tion, 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 fol-
lowing 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:
1. Disconnect the spark plug wire on the engine and release all air tank pres-
sure.
2. Remove belt guard.
3. Place a straightedge
against the outside of
the flywheel and the
engine drive pulley.
4. Measure the distance
between the edge of
the belt and the
straightedge at points
A1 and A2 in Figure.
The difference 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.-lbs.
7. Visually inspect the engine drive pulley to verify that it is perpendicular to
the drive motor shaft. Points B1 and B2 of Figure 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
in step 2.
8. Retighten the engine drive pulley setscrew to 70-80 in.-lbs.
9. Reinstall belt guard.
10. Reconnect spark plug wire to spark plug on engine.