Porter-Cable CPL6025 User manual

Oillube Single-Stage
Portable Compressor
IMPORTANT
Please make certapn that the person who us to use
thus equipment carefully reads and understands
these mstruchons before sta_ng operations
RtoP_scx_w.Pow_ toOLS
The Model and Sernal No plate IS located on the
frame Record these numbers in the spaces below
and retain for future reference
Model NO
Type
Senal No
Part NO D24938-103-1

SAFETY GUIDELINES -DEFINITIONS
This manual contains information that isimportant 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.
PR_:I_,[€__=l=l ImL!]I:_l[s]_]
DANGER indicates an imminently CAUTION indicates a potentially
hazardous situation which, if not hazardous situation which, if not
avoided, will result in death or avoided, may result in
_. moderate iniurv,
_...,IJlI[o]_rl
WARNING indicates a potentially CAUTION used without the safety
hazardous situation which, if not alert symbol indicates a potentially
avoided, cgJ_ result in td_ hazardous situation which, if not
_. avoided, may. result in
damaoe.
Call our Toll Free Number 1-888-559-855_ 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
I_ When using electric tools, basic safety precautions
should always be followed to reduce the risk of firs, electric shock
and personal injury, including the following:
READ AND FOLLOW ALL INSTRUCTIONS,
This tool was designed forcertain applications, Porter-Cable stronglyrecommends
that this tool NOT be modified and/or used for any application, other than for which
it was designed, If you have any questions relativeto its application DO NOT use
the tool untilyou have written Porter-Cable and we have advised you,
Technical Service Manager
Porter-Cable Corporation
4825 Highway 45 North
P.O. Box 2468
Jackson, TN 38302-2468
D_4_8 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 WILL CAUSE SERIOUS
OVERHEATING AND COULD CAUSE FIRE.
UNA37-ENDED OPERATION OF THIS PRODUCT
COULD RESULT IN PERSONAL INJURY OR
PROPERTY DAMAGE.
ALWAYSOPERATE 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 AREAAT 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 ATTENDANCEWITH THE
PRODUCTWRENIT ISOPERATING.
RISK OF BURSTING I_
A/R TAN_- THEFOLLOWINGCONDITIONSCOULDLEADTOAWEAKENINGOFTHETANK,ANDRESULT
INA VIOLENTTANKEXPLOSIONAND COULD CAUSEPROPERTYDAMAGEOR SERIOUS INJURY.
I,
2,
3,
4,
WHAT CAN HAPPEN
FAILURE TO PROPERLY DRAIN CON
DENSED WATER FROM THE TANK,
CAUSING RUST AND THINNING OF THE
STEEL TANK
MODIFICATIONS OR ATI EMPTED REPAIRS
TO THE TANK.
UNAUTHORIZED MODIFICATIONS TO THE
UNLOADER VALVE, SAFETY VALVE, OR
ANY OTHER COMPONENTS WHICH
CONTROL TANK PRESSURE.
EXCESSIVE VIBRATION CAN WEAKEN THE
AIR TANK AND CAUSE RUPTURE OR
EXPLOSION.
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 APAEI
AND COULD RESULT IN SERIOUS INJURY,
HOW TO PREVENT IT
DRAIN TANK DAILYOR AFTER EACH USE. IFTANK
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 ATTACHMENTS NEVER
USE COMPRESSOR TO INFLATE SMALL LOW-
PRESSURE OBJECTS SUCH AS CHILDREN'S
TOYS, FOOTBALLS, BASKETBALLS. ETC.
3-ENG D24938

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 SPRAYERTOWARD
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 ATIEMPTING MAINTENANCE,
ATTACHING TOOLS OR ACCESSORIES,
RISK TO BREATHING
WHAT CAN HAPPEN
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,
HOW TO PREVENT IT
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 INSERIOUS INJURY OR
DEATH BY ELECTROCUTION.
ELECTRICAL GROUNDING: FAILURE TO PROVIDE
ADEQUATE GROUNDING TO THIS PRODUCT
COULD RESULT IN SERIOUS INJURY OR DEATH
FROM ELECTROCUTION, SEE GROUNDING
INSTRUCTIONS.
HOW TO PREVENT IT
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 GROUNDING,
CORRECT VOLTAGE AND ADEQUATE FUSE
PROTECTION.
D_4938 4-ENG

IMPORTANT SAFETY INSTRUCTIONS (cont'd)
RISK FROM MOVING PARTS ----_I
WHAT CAN HAPPEN
MOVING PARTS SUCH AS THE PULLEY,
FLYWHEEL, AND BELT CAN CAUSE SERIOUS
INJURY IFTHEY COME INTO CONTACT WITH YOU
OR YOUR CLOTHING,
ATTEMPTING TO OPERATE COMPRESSOR WITH
DAMAGED OR MISSING PARTS OR AI"rEMPTING
TO REPAIR COMPRESSOR WITH PROTECTIVE
SHROUDS REMOVED CAN EXPOSE YOU TO
MOVING PARTS AND CAN RESULT IN SERIOUS
INJURY.
HOW TO PREVENT IT
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_,,,,
WHAT CAN HAPPEN HOW TO PREVENT IT
TOUCHING EXPOSED METAL SUCH AS THE NEVERTOUCNANYEXPOSED METALPARYSON
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 IHOW TO PREVENT IT
A PORTABLE COMPRESSOR CAN FALL FROM A IALWAYS 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
INJURYORDEATH CAN RESULT. OILLEAKSWILL AGAINST DAMAGE TO VEHICLE FROM LEAKS
DAMAGE CARPET, PAINT OR OTHER SURFACES REMOVE COMPRESSOR FROM VEHICLE
INVEHICLESORTRAILERS IMMEDIATELY UPON ARRIVAL AT YOUR
DESTINATION.
E$_99 -- 9/2_g
5-ENG [324938

GLOSSARY
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per minute; a unit of measure ofair delivery.
PSlG: Pounds per square inch gauge; a unitof measureof pressure.
ASME: American Society of Mechanical Engineers; made, tested, inspected, and
registeredto meet the standards ofASME.
California Code: Unit may comply with California Code 462 (_ (2)/(M) (2).
Specification/model label is on the side ofthe tank on units that comply with
California Code.
Cut-In Pressure: While the motor is off, air tank pressuredrops 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 pressureat which the motor
automatically restarts is called "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 buildsto a certain high pressure before
the motor automatically shuts off - protecting your air tank from pressure higher
than its capacity. The high pressureat which the motor shuts off is called "cut-out
pressure."
Code Certification: Products that bear one or more of the following marks: UL,
CUL, E-I'L,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 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.
SPECIFICATIONS
Model No. CPL6025
Horsepower Peak 6.0
Bore 2.875
Stroke 2.0
* Voltage-Single Phase 120
** Minimum Branch Circuit Requirement 15 amps
* FuseType Time Delay
Air Tank Capacity (Gallon) 25 ASME
Approximate Cut-in Pressure 110 PSIG
Approximate Cut-out Pressure 135 PSIG
SCFM @40 PSIG 8.6
SCFM @90 PSIG 6.8
* I_ 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
a 20 amp circuit. It is not necessary to change the cord set.
** A circuit breaker ispreferred. 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 acircuit protected by fuses, use dual element time delay fuses.
D24938 6-ENG

DESCRIPTION OF OPERATION
Drain Valve (A)Fig. 1: The drain valveislocatedat the base of
the air tank and isusedto drain condensationat the end of
each use.
Motor Thermal Overload Protector (not shown)= The
electric motorhas an automaticthermal overloadprotector. If
the motor overheats for any reason, the thermal overload \
protector willshut off the motor. The motor must be allowed to A
cool before restarting. ON/AUTO- Fig. 1
BGD OFF Switch (B) Fig. 2: Turnthis
switchON to provide automatic
power tothe pressureswitchand
OFF to remove powerat the end of
each use.
Air Intake Rlter (not shown): This
filter is designed toclean air coming
into the pump. This filter must always
be clean and ventilation openings
freefrom obstructions. See
"Maintenance".
Air Compressor Pump (not shown):
Tocompressair,the pistonmovesup
and down inthe cylinder. On the
Fig. 2 downstroke, air isdrawnin through
the air intakevalves.The exhaust
valve remainsclosed. On the upstrokeof the piston,air iscompressed. The intake
valvescloseand compressedairisforced outthroughthe exhaustvalve, intothe outlet
tube, throughthe check valveand intothe airtank. Workingair isnot availableuntilthe
compressorhasmieed the airtank pressureabove thatrequiredat the air outlet.
Check Valve (C) Fig. 2:. Whenthe air compressorisoperating,the checkvalve is
"open", allowing compressedair to enterthe airtank. When the aircompressor
reaches"cut-out"pressure,the checkvalve "closes", aUowingair pressure to remain
insidethe air tank.
P_ssure Release Valve (I) Rg. 2: The pressurereleasevalvelocatedon the sideof
the pressure switch, isdesignedto automaticallyreleasecompressedairfromthe
compressorhead andthe outtettube whenthe aircompressorreaches"cut-out"
pressureor isshutoft. The oreasuro release valveallowsthe motorto restartfreely.
When the motor etODSrunnino,air willbe heardeecaDino fromthisvalvefora few
seconds. No airshouldbe heardleekinewhen the motorisrunnino,or continuous
leekinoafter unit reachescut-out Dressure.
Pressure Switch (D) Fig. 2: The pressureswitchautomaticallystartsthe motorwhen
the airtank pressuredropsbelowthe factoryset "cut-in" pressure. Itstops the motor
when the airtank pressure reachesthe factoryset "cut-out" pressure.
Safety Valve (E)Fig. 2: Ifthe pressureswitchdoes notshutoffthe aircompressorat its
cut-out pressure setting,the safetyvalvewillprotectagainsthighpressure by "popping
out"at its factoryset pressure (slightS/higherthan the pressureswitchcat-out setting).
Outlet Pressure Gauge (P)Fig. 2: The outlet pressure gauge indicatesthe air pressure
availableat the outletsideofthe regulator. This pressureis controlledby the regulator
and isalwayslessthanor equalto the tank pressure.
Tank Pressure Gauge (G)Fig. 2: The tank pressuregauge indicatesthe reserve air
pressureinthe tank.
Regulator (H) Fig. 2: The airpressurecoming fromthe airtank iscontrolled by the
regulatorknob. Turnthe knobclockwiseto increasepressureand counterclockwiseto
decrease pressure.Toavoidminorreadjustmentafter makinga change inpressure
setting,alwaysapproach the desired pressure from a lower pressure. When reducing
from ahigher to a lower setting,first reduceto some pressureless than thatdesired,
then bring upto the desired pressure.Depending on the airrequirementsofeach
particularaccessory,the outletregulatedair pressuremay have to be adjustedwhile
you are operatingthe accessory.
7-ENG D24938

INSTALLATION
Items Needed for Assembly
a9/16" socketor open-end wrenchfor attaching the wheels
Installing Wheels and Rubber Foot Strip
I_ It may be necessary to brace or support one end of the
unit when attaching the wheels because the air compressor will have
atendency to tip.
1. Attach rubber feet with the screws, washers and nutsprovided. Tighten securely.
2. Place shoulder boltthrough wheel and position it intothe top hole of the
mounting bracket (protruding hubto the inside)• Thread nut onto shoulder bolt
and tighten firmlywith a 9/16" wrench. Repeat to install second wheel.
Installing Handle
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 RAMP. DO NOT LIFT THE UNIT BY THE
MANIFOLD ASSEMBLY. THE UNIT CAN BE DAMAGED.
1. Submerge handle grip into warm soapy water to make installationeasier.
Remove handle grip from soapy water and slide onto handle.
2. Insert the open end of the handle under the saddle (Fig. 3). Before attaching
handle, you may have to pull the open ends of the handle apart so they fit
tightly against the side of the saddle. Looking in from the open end of the
saddle, position the handle toward the two bent tabs, on the inside walls of the
saddle. Slowly push the open ends of the handle onto both tabs at the same
time (Fig. 4). Continue pushing the handle into the saddle until the holes on the
side of the saddle and handle are in line.
3. Guide the straight end of each retaining clip through the saddle hole and both
handle holes (Fig. 5).
B_NT TAIB _1_
Fig. 3 Fig. 4
E_4938 8 ENG

4. Rotate each retaining clip clockwise and press down until it snaps into place
over the pull handle (Fig. 6).
5. Ifthe handle has excessive movement, it is improperly installed. Check the
following. .... \t
/_' i '
_-" -= li '
ONT_
Fig. 5
BELT $
Fig. 6
A. Are both tabs inside the handle (Step #1)?
B. Does each clip pass through both the saddle and handle (Step #2)?
Location of the Air Compressor
Operate the aircompressor in aclean, dry, and well-ventilated area. The flywheel
must be kept clear of obstructions that could interfere with the flow of air through
the air intake filter. The pump crankcase and head are designed with fins to provide
proper cooling.
If humidity is high, an air filter can be installed on the air outlet adapter to remove
excessive moisture. Closely follow the instructionspackaged with the filter for
proper installation. It must be installed as close as possible to the accessory. Do not
place the air compressor where heat isexcessive.
When locatingthe compressor outside, make surethere isa minimumof 12 inches
on each side of the compressor. The unit requires fresh air flow for proper cooling.
DO NOT ALLOW THE COMPRESSOR TO GET WET.
Lubrication and Oil (Fig. 7)
Multi-Viscosity motor oils, like lOW 30, should not be
used in an air compressor. They leave carbon deposits on cdtical
components, thus R_lucing performance and compressor life. U_,u3Jr
comoressor oil only.
Oil
NOTE
Use aair compressor oil such as SAE-20 (API CG/CD heavy duty).
Under extreme winter conditions use SAE-10 weight oil.
Comoressors are shioDedwithout oil. A small amount of
oil may be present in the pump upon receipt of the air compressor. This
isdue to plant testing and does not mean that the pump contains oil. Do
notattempt to operate this air compressor without first adding oilto the
crankcase. Serious damage can result from even limited operation
unless filled with oil and broken in correctly. Make sure to
closely follow initial start-up procedures.
Drain tank to release air pressure before removing the oil
fill cap or oil drain plug
9-ENG [3'24938

Place uniton a level surface. Remove oil fill plug (A) and
slowly add a compressor oil until it is even with the top
of the oil fill hole. (It must not be allowed to be lower
than 3/8" -6 threads down -from the top at any time.)
When filling the crankcase, the oil flows very slowly into
the pump. If the oil is added too quickly, itwill overflow
and appear to be full. Crankcase oil capacity is
approximately 16 fluid ounces. Replace oil fill plug.
NOTE
Drain end refill the compressor pump crankcase
after the first 1O0hours of operation,
Extension Cords
Fig. 7
To avoid voltage drop and power lossto the motor, and to prevent overheating, use
extra air hose instead of an extension cord.
Ifan extension cord must be used:
• useonly a 3-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 your Parfs Manualfor voltage and circuitprotection requirementsof your
compressor. Use onlyafuse or circuitbreakerthat isthe sameratingas the branch
circuiton whichthe air compressorisoperated. If the compressoris connected to a
circuit protected by fuses, use onlydual element time delay fuses.
Piping
I_ 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 lineis necessary, use pipe that is the same size as the airtank outlet.
Piping that istoo smallwill restrict the flow of air. If piping is over 100 feet long, use
the next larger size. Bury underground lines below the frost lineend avoid pockets
where condensation can gather and freeze. Apply pressure before underground
lines are covered to make sure ell pipe joints are free of leaks.
Connect the piping to the 3/8" NPT air outlet opening at the end of the air tank.
D24938 10-ENG

GROUNDING INSTRUCTIONS
RISK OF ELECTRICAL SHOCK] In the event of ashort
circuit, grounding reduces the risk of shock by providing an escape
wire for the electric current. This air compressor must be properly
grounded,
If these grounding instructionsare net completely understood, or if in doubt as to
whether the compressor is properly grounded, have the installationchecked by a
qualified electrician. The air compressor is equipped with a cord having a
groundingwire with an appropriate groundingplug. The plug must be usedwith an
outlet that has been installed and grounded in accordance with all local codes and
ordinances. The outlet must have the same
configuration as the plug. See Fig. 8. DO NOT USE
AN ADAPTER.
Inspect the plug and cord before each use. Do not
use if there are signsof damage.
I_'='_ Improper grounding can result
in electrical shockZ
Do notmodify the plugthat has been provided. If it
does net fit the available outlet, the correct outlet
should be installedby a qualified electrician.
If repairing or replacingcord 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
insulationwith an outer surface that isgreen -with or
without yellowstripes.
120 Volt Models
White
15Amp Plug Outlet
nGrounded._------_
Pin
Fig. 8
Additional Regulators and Controls
Since the air tank pressureis usuallygreater than that which isneeded, a separate
regulator isusuallyemployed to control the air pressureahead of any individual air-
driven device.
11-ENG D249_8

BREAK-IN PROCEDURES
I_ Serious damage may result if the following break-in
instructions are not closely followed.
This procedure is required before the air compressor is put intoservice. (before the
hose is installed), the check valve isreplaced, or a complete compressor pump is
replaced.
The procedure:
1. Make surethe 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. Runthecompressorfor 30minutes. Make sure the drain valve is open and there
is minimal air pressure build-up in tank.
6. After 30 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
t. Before attaching air hoseor accessories, make sure the ON/AUTO leveris setto
"OFF" and the air regulatoris 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 pressurereaches "cut-out" pressure.
4. Open the regulator by turning it clockwise. Adjust the regulator to the correct
pressuresetting. Yourcompressor isready 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" leverto "OFF".
7. Turnthe regulatorcounterclockwise 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 untiltank pressureis
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.
D249_8 12-ENG

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.
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 longerlife ofthe air compressor unit,a routine
maintenance schedule should be prepared and followed. The following routine
maintenance schedule is geared to an unitin a normal working environment
operating ona daily basis. If necessary,the schedule should be modified to suit the
conditions under whichyour compressor is used. The modifications will depend
uponthe 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.
Routine Maintenance Schedule
Daily:
1. Pullring on safety valve allowing airto bleed from the tank untiltank pressureis
approximately 20 psi. Release safety valve ring.
2. Check oil level. Add if necessary.
3. Drain water from the air tank, any moistureseparators, or transformers.
4. Check for any unusual noise and/or vibration.
5. Manually check safety valve to make sure of proper operation.
6. Inspect air filter and replace if necessary.
7. Inspect air filter and replace if necessary.
Every 40 Hours of Operation:
1. Clean and inspect the air intake filter; replace ifnecessary.
2. Inspect condition of drive belt and replace if necessary.
Every 100 Hours of Operation:
1. Drain and refillcompressor crankcase with approximately 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, and adjust if necessary. (Refer to SERVICE INSTRUC-
TIONS in this manual.)
2, Inspect air lines and fittings for leaks; correct as necessary.
3. Check the alignment of the motor pulleyto the flywheel. If necessary, align to
within 1/32 inch on center line.
Each Year of Operation or ff a Problem is Suspected:
Check condition of air compressor pump intake and exhaust valves, Replace if
damaged or worn out.
13-ENG 024938

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.
A dirty air filter will not allow the compressor to operate at full capacity, Before you
use the compressor,check the airfilter to be sure it is clean,
if itis dirty, replace it with a new filter,The filter may be removed by using a pairof
needle nosed pliersor a screwdriver, Pullor pry out the old filter, Push in the new
air filter,
Oil - Checking and Changing
Drain tank to release air pressure before removing the oil
fill cap or oil drain plug
I_ Overfilling with oil will cause premature compressor
failure. Do not overfill,
Check oil level inthe crankcase daily. Remove the oil fill D_UO.The oil levelshould be
even with the too of the fill hole and must not be allowed to be lower than 3/8" from
the ted (6 threads_at aqytim_. It isrecommended that the oil be changed after every
100 hours of operation.To drain the oil, removethe oil drain plug and collect the oil
in asuitable container.Be sureto replace the plugsecurely beforeadding new oil.
Use a air compressor oil suchas SAE-20 (API CG/CD heavy duty). Under extreme
winter conditionsuse SAE-10 weight oil. Crankcase oil capacity isapproximately 16
fluid ounces (473.2 ml).
Check Valve -Inspection and Replacement
Remove and inspect the check valve at least once a yearor more oftenifthe
compressor isheavily used. Moisture and other contaminants in the hot
compressed air will cause an accumulation of a carbon-like residue onthe working
parts. If the valve has heavy carbon build-up, it should be replaced. Use the
following procedure to inspect, clean or replace the check valve.
1. Unplug compressor. Release air pressurefromthe air tank.
2. Loosenthe top and bottom tube nuts and remove the outlet tube.
3. Unscrew the check valve using socket wrench (7/8").
4. Check that the valve disc moves freely and that the spring holds the disc in the
upper, closed position. The check valve may be cleaned with a solvent.
5. Apply sealant to the check valve threads. Reinstall the check valve. Do not
overtighten.
6. Replace the outlet tube and tighten top and bottom tube nuts.
Safety Valve -Inspection and Replacement
IF THE SAFETY VALVEDOES NOT WORK PROPERLY,
OVER-PRESSURIZATION MAY OCCUR CAUSING AIR TANK RUPTURE
OR EXPLOSION. DAILY PULL THE RING ON THE SAFETY VALVETO
MAKE SURE THAT THE SAFETY VALVE OPERATES FREELY. IF THE
VALVEIS STUCK OR DOES NOT OPERATE SMOOTHLY, IT MUST BE
REPLACED WITH A VALVE HAVING THE SAME PRESSURE RATING.
Belt -Replacement
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
COMPRESSOR IS UNPLUGGED.
D249_38 14-ENG

k
Belt Guard - Removal and Installation
1. Move the "ON/AUTO-OFF" leverto the "OFF" position. Unplug the compressor.
Release all airtank pressure.
2. Remove the front of the belt guard by disengaging the snaps. Insert a flat bladed
screwdriver at each snap location and pry the beltguard apart.
Replace Belt
1, Unplug Compressor.
2. Remove beltguard as described above.
NOTE
Loosen the wing nut at the hold down plate. The motor can be tilted to
allow for easy removal or installation of the belt.
3. Remove belt and replace. NOTE
The belt must be cente_l over the grooves on the flywheel and motor
pulley.
Adjust Belt Tension
Adjust belt tension by tightening the wing nut until it makes contact with the
washer, plus one additional turn.
Pressure Switch -Replacement
PRESSURE LOADS BEYOND DESIGN LIMITS MAY
CAUSE TANK RUPTURE OR EXPLOSION, PRESSURE SWITCH
OPERATION IS RELATED TO MOTOR HP, TANK RATING AND SAFETY
VALVE SE'rFING. DO NOT A'n'EMPT TO ADJUST, REMOVE, OR
DEFEAT THE PRESSURE SWITCH, OR CHANGF-JMODIFY ANY
PRESSURE CONTROL RELATED DEVICE. IF REPLACEMENT IS
NECESSARY, THE SAME RATED SWITCH MUST BE USED. CONTACT
AN AUTHORIZED SERVICE CENTER FOR REPLACEMENT.
Motor Overload Protector -Reset (Fig. 9)
The motor has amanual thermal overload protector. If the motor overheats forany
reason, the overload protector will shut off the motor.
The motor must be allowed to cool down before
restarting. Turn the unit off. To restart, depress the red
reset button (A)located on the end of the motor and turn
ON/AUTO-OFF switch to the ON position.
NOTE
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 Fig. 9
speed.
2. Fuses blow outwhen the motor is started.
3. Lights dim when motor isstarted, and remain dim while it is
running.
15-ENG [}24938

Pulley and Flywheel - Alignment
The compressor flywheel and motor pulley grooves must be in-linewithin 1/32" to
assurebelt a_ignment within sheave grooves. To check alignment, unplug
compressor and remove the beltguard. Place a straight edge against the outside of
the flywheel and measure the distance from it to the nearest groove. Alignment is
achieved when the other end of the straight edge iswithin 1/32" of the measured
dimension at the pulley grooves•
Servicing Intake and Exhaust Valves
The intake and exhaust valves as well as the valve plates and cylinder headwill,
over aperiod of time, accumulate aresidue of carbon-like material on their
surfaces. The material will decrease the efficiency of the compressor. These
components should be inspected whenever a problem is suspected and cleaned or
replaced with new parts. Use the following procedure to inspect the parts.
1. Unplug compressor and relieve all air pressure from the air tank.
2. Disconnect the pressure release and outlet lines from the air compressor.
3. Remove the hardware securing the cylinder head and 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
compressor valve cavities and air flow areas.
6. Reinstall valve plate and gaskets.
7. Install the cylinder head. Snug mounting screws and studs tight, then torque to
25 to 30 foot pounds starting at the center and working toward the outside.
8. Reconnect the pressurerelease and outlet lines to the compressor pump.
STORAGE
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. Remove the air tool or accessory.
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 sir 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.
024938 16-ENG

NOTE
If drain cock valve is plugged, 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 unit handle.
g. Store the compressor in aclean, and dry location.
TROUBLESHOOTING GUIDE
PERFORMING REPAIRS MAY EXPOSE VOLTAGE
SOURCES, MOVING PARTS OR COMPRESSED AIR SOURCES.
PERSONAL INJURY MAY OCCUR. PRIOR TO A'n'EMPTING ANY
REPAIRS, UNPLUG THE AIR COMPRESSOR AND BLEED OFF ALL AIR
TANK AIR PRESSURE.
PROBLEM
Excessive tank
pressure - safety
valve pops off.
CAUSE
Pressure switch does not shut
off motor when compressor
reaches "cut-out" pressure.
CORRECTION
Move the pressure switch lever to
ithe "OFF" position. If the unit
doesn't shut off, and the electrical
contacts are welded together,
replace the pressure switch.
If the contacts are good, check to
:see if the pin in the bottom of the
,pressure release valve isstuck. If it
does not move freely, replace the
valve.
Pressure switch "cut-out" too Return the unitto an Authorized
high. Warranty Service Center to check,
remove or replace switch.
Air leaks at fittings. Tube fittings are net tight Tighten fittings where air can be
enough, heard escaping. Check fittings with
soapy water solution. DO NOT
OVER-TIGHTEN.
Air leaks at or inside Malfunctioning or dirty check A malfunctioning check valve results
check valve, valve, in a constant air leakat the pressure
release valve when pressure is in the
tank and the compressor is shut off.
Remove and clean or replace check
valve. DO NOT OVER-TIGHTEN.
Airleaks at pressure Malfunctioning pressure switch Remove and replace the release
switch release valve, release valve, valve.
Malfunctioning check valve. A malfunctioning check valve results
in a constant air leak at the pressure
release valve when pressure is in the
tank and the compressor is shut off.
Remove and clean or replace check
valve. DO NOT OVER-TIGHTEN.
17-ENG D24938

PROBLEM
Air leaks in air tank o_
at air tank welds.
Air leak from safety
valve.
Knocking noise
Restricted air intake
Compressor is not
supplying enough
air to operate
accessories.
CAUSE
Damagedairtank.
Possible defect in safety
valve
Restricted or malfunctioning
check valve.
Loose pulley.
Low oil level.
Loose flywheel.
Loose compressor mounting
screws.
Loose belt.
Belt too tight.
Carbon build-up.
Dirty air filten
Prolonged excessive use of air.
Compressor is not large
enough for air requirement.
Restricted air intake filten
Loose belt.
Hole in hose.
Check valve restricted.
Air leaks.
CORRECTION
Air tank must be replaced. Do not
repair the leak.
• _r_ DO NOT DRILL
INTO, WELD, OR OTHERWISE
MODIFY AIR TANK OR IT WILL
WEAKEN. THE TANK CAN
RUPTURE OR EXPLODE.
Operate safety valve manually by
pulling on ring. if valve still leaks, it
must be replaced.
Remove and clean or replace.
Torque pulley set screw.
Maintain prescribed oil level. Add
oil.
Torque screw 15-20 ft. Ibs.
Check screws. Torque as required
15-20 ft.-Ibs.)
Tighten wing nut until it contacts
the washer, plus one more turn.
Adjust belt tension (see "Belt
Replacement" .)
Remove the head and valve plate.
Clean the valve plate and top of the
piston. (Be sure carbon does not fall
into the cylinder.) Reassemble to
25-30 ft. Ibs. Using new gasket and
torque screws.
Replace filter.
Decrease amount of air usage.
Check the accessory air
requirement. If it is higher than the
CFM, SCFM or pressure supplied
by your air compressor, you need a
larger compressor.
Clean or replace air intake filter. Do
not operate the compressor in the
paint spray area.
Adjust belt tension.
Check and replace if required.
Remove and clean or replace.
Tighten fittings. (See "Air Leaks"
section of "Troubleshooting Guide".)
D24938 18 ENG

CAUSE
Motor overload protection
switch has tripped.
PROBLEM
Motorwillnot run.
Possible malfunctioning
capacitor.
Possible malfunctioning motor.
Tank pressure exceeds
)ressure switch "cut-in"
)ressure.
Check valve stuck open - falls
to relieve head pressure;
motor cannot start.
Loose electrical connections,
Fuse blown, circuit breaker
tnpped.
Pressure release valve on
)ressure switch has not
unloaded head pressure,
Paint spray on internal motor
)arts.
CORRECTION
Let the motor cool off and reset
switch by pressing the red button
located on the end of the motor. If
the ovedoed stilltdps. check for
malfunctioning capacitor.
Return to Service Center for
inspection or replacement if
necessary.
Have checked at a local Authorized
Warranty Service Center.
Motor will start automatically when
tank pressure drops below "cut-in"
pressure of pressure switch.
Remove and clean, or replace. DO
NOT OVER-TIGHTEN.
Check widng connection inside
)ressure switch and motor terminal
box area.
1. Check fuse box for blown fuse
and replace it 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.
4. Remove check valve and clean
or replace if it is stuck open or
closed,
5. Disconnect any other electrical
appliances from circuit. The
compressor must operate on its
own branch circuit,
Do not use an extension cord.
Bleed the line by pushing the lever
on the pressure switch to the OFF
position, opening the pressure
release valve. If the valve still
doesn't open, it must be replaced,
Have checked at an Authorized
Warranty Service Center.
Do not operate the compressor in
the spray area. See Flammable
Vapor Warning.
19-ENG [324938

PROBLEM CAUSE CORRECTION
Excessivebeltwear, Beltistoolooseortight,
Squealing sound.
Pressure reading on
the regulated
pressure gauge
drops when an
accessory is used.
Regulator knob -
continuous air leak.
Regulator will not
shut off at air outlet.
Loose pulley.
Pulley misalignment.
Loose belt.
There is no oil inthe
compressor.
It is normal for "some"
pressure drop to occur.
Dirty or damaged regulator
internal parts.
Adjust tension instructions. (See
"Belt Adjustment or Replacement"
section in this manual.
Check for worn keyway or pulley
bore. Also check for bent motor
shaft. Replace parts if necessary.
Motor pulley and flywheel must be
in line within 1/32". (See "Pulley and
Flywheel - Alignment" section in this
manual.)
Adjust belt tension. (See "Belt
Replacement" section in this
manual.)
Add oil to top of fill hole in base.
If there is an excessive amount of
=ressuredrop when the accessory
is used, adjust the regulator.
NOTE
Adjust the regulated pressure
under flow conditions (while the
accessory is being used).
Clean or replace regulator or
internal parts,
D24938 20-ENG