Porter-Cable CPLDC2541S User manual

Direct Drive
Oil Lube
Portable Air Compressor
CPLDC2541S
To learnmoreabout pbrtei;_Cbbie
visitourwebsite ati
IMPORTANT
Please make certain that the person who is
to use this equipment carefully reads and
understands these instructions before
starting operations.
The Model and Sehal No. plate is located on the frame,
Record these numbers in the spaces below and retain for
future i_ference.
Model No.
Type
Sedal No.
Copyright 02001 Porter_able;Corporation Part No. D24064-0111-1

SAFETY GUIDELINES - DEFINITIONS
This manual contains information that is important for you to know and understand. 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 sections.
situationwhich, if not avoided, will
result in death or serious iniurv.
_lndicates a potentially
hazardous situation
which, if not avoided,_ result in
death or serious iniuw.
_l_lndicates a potentially
hazardous situation
which, if not avoided, may result in
minor or moderate iniurv.
_rr_=_ Used withoutthe
safety alert symbol
indicatesa potentially hazardous
situation which, if not avoided, may
result in Property damaae.
IMPORTANT SAFETY INSTRUCTIONS
Some dust created by power sanding, sawing, grinding, drilling, and other
construction acfivitJes contains chemicals known (to the State of California) to
cause cancer, birth defects or other reproductive 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 ventilated 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.
READ AND FOLLOW ALL INSTRUCTIONS.
This tool was designed for certain applications, porter-Cable strongly recommends that this tool NOT
be modified and/or USed for any application other than for which it was designed. If you have any
questions relative to its application DO NOT use the tool until you have written Porter-Cable and we
have advised you.
Technical Service Manager
Porter-Cable Corporation
4825 Highway 45 North
PO. Box 2468
Jackson, TN 38302-2468
D24064 2- ENG

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 OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT.
HAZARD
RISK OF EXPLOSION OR FIRE
WHAT CAN HAPPEN HOWTO PREVENT IT
IT IS NORMAL FOR ELECTRICAL CONTACTS
WITHIN THE MOTOR AND PRESSURE SWITCH
TO SPARK,
IF ELECTHICAL 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.
UNATrENDED OPERATIONOFTHIS
PRODUCT COULD RESULTIN PERSONAL
INJURY OR PROPERTY DAMAGE.TO
REDUCE THE RISK OF FIRE,DO NOT ALLOW
THE COMPRESSOR TO OPERATE
UNAI"rENDED.
ALWAYS OPERATE THE COMPRESSOR IN A
WELL VENTILATED AREA FREE OF
COMBUSTIBLE MATERIALS, GASOLINE OR
SOLVENT VAPORS.
IF SPRAYING FLAMMABLE MATERIALS,
LOCATE COMPRESSOR AT LEAST 20 FEET
AWAY FROM SPRAY AREA. AN ADDITIONAL
LENGTH OF HOSE MAY BE REQUIRED.
STORE FLAMMABLE MATERIALS IN A
SECURE LOCATION AWAY FROM
COMPRESSOR.
NEVER PLACE OBJECTS AGAINST OR ON
TOP OF COMPRESSOR. OPERATE
COMPRESSOR IN AN OPEN AREA AT LEAST
12 INCHES AWAY FROM ANY WALL OR
OBSTRUCTION _'IAT WOULD RESTRICT THE
FLOW OF FRESH AIR TO THE VENTILATION
OPENINGS.
OPERATE COMPRESSOR IN A CLEAN, DRY,
WELLVENTILATED AREA. DO NOTOPERATE
UNIT INDOORS OR IN ANY CONFINED AREA.
ALWAYS REMAIN IN AI-rENDANOE WITH THE
PRODUCT WHEN IT IS OPERATING.
ALWAYS DISCONNECT ELECTRICAL POWER
BY MOVING PRESSURE SWITCH LEVER TO
THE OFF POSITION AND DRAIN TANK DAILY
OR AFTER EACH USE,
3- ENG D24064

HAZARD
RISK OF BURSTING I_.1
THE FOLLOWINGCONDITIONS COULD LEADTO AWEAKENING OF THE
TANK, AND RESULT IN A VIOLENT TANK EXPLOSION AND COULD CAUSE
PROPERTY DAMAGE OR SERIOUS INJURY.
WHAT CAN HAPPEN
I. FAILURE TO PROPERLY DRAIN
CONDENSED WATER FROM THE
TANK, CAUSING RUST AND THINNING
OF THE STEEL TANK.
2. MODIFICATIONS OR A'R'EMPTEO
REPAIRS TO THE TANK.
3. UNAUTHORIZED MODIFICATIONS TO
THE UNLOADER VALVE, SAFETY
VALVE, OR ANY OTHER COMPONENTS
WHICH CONTROL TANK PRESSURE.
4. EXCESSIVE VIBRATION CAN WEAKEN
THE AIR TANK AND CAUSE RUPTURE
OR EXPLOSION.
ATEACHMENTS &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 ]NJUR_
HOW TO PREVENT IT
DRAIN TANK DAILY OR AFTER BACH USE. IF
TANK DEVELOPS A LEAK, REPLACE IT
IMMEDIATELY wn_ A NEW TANK OR REPLACE
THE ENTIRE COMPRESSOR.
NEVER DRILL INTO, WELD, OR MAKE ANY
MODIFICATIONS TO THE TANK OR ITS
AT[ACHM ENTS.
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 (IF NOT EQUIPPED) OF YOUR
COMPRESSOR. FOLLOW THE EQUIPMENT
MANUFACTURERS RECOMMENDATION AND
NEVER EXCEED THE MAXIMUM ALLOWABLE
PRESSURE RATING OF ATrACHMENTS. NEVER
USE COMPRESSOR TO INFLATE SMALL LOW-
PRESSURE OBJECTS SUCH AS CHILDREN'S
TOYS, FOOTBALLS, BASKETBALLS, ETC.
HAZARD
RISK FROM FLYING OBJECTS
WHAT CAN HAPPEN HOW TO PREVENT IT
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.
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 ATrEMPTING MAINTENANCE,
AT[ACHING TOOLS OR ACCESSORIES.
D24064 4- ENG

HAZARD
RISK OF ELECTRICALSHOCK
WHAT CAN HAPPEN
YOUR AIR COMPRESSOR IS POWERED BY
ELECTRICITY. UKE ANY OTHER
ELECTRICALLY POWERED DEVICE, IF IT IS
NOT USED PROPERLY IT MAY CAUSE
ELECTRIC SHOCK.
REPAIRS ATTEMPTED BY UNQUALIFIED
PERSONNEL CAN RESULT IN SERIOUS
INJURY OR DEATH BY ELECTROCUTION.
ELECTRICAL GROUNDING: FAILURE TO
PROVIDE ADEQUATE GROUNDING TO THIS
PRODUCT COULD RESULT IN SERIOUS
INJURY OR DEATH FROM ELECTROCUTION.
SEEGROUNDING INSTRUCTIONS
HOW TO PREVENT IT
NEVER OPERATE THE COMPRESSOR
OUTDOORS WHEN IT IS RAINING OR IN WET
CONDITIONS
NEVER OPERATE COMPRESSOR WITH
PROTECTIVE COVERS REMOVED OR
DAMAGED.
ANY ELECTRICAL WIRING OR REPAIRS
REQUIREDON THIS PRODUCT SHOULD BE
PERFORMED BY AUTHORIZED SERVICE
CENTER PERSONNEL IN ACCORDANCEWITH
NATIONALAND LOCALELECTRICALCODES.
MAKE CERTAIN THAT THE ELECTRICAL
CIRCUIT TO WHICH THE COMPRESSOR IS
CONNECTED PROVIDES PROPER
ELECTRICAL GROUNDING, CORRECT
VOLTAGE AND ADEQUATE FUSE
PROTECTION.
HAZARD
RISK TO BREATHING
WHAT CAN HAPPEN HOW TO PREVENT IT
THECOMPRESSED AIR DIRECTLYFROM
YOURCOMPRESSOR IS NOT SAFE FOR
BREATHING. THEAIR STREAM MAy
CONTAIN CARBON MONOXIDE, TOXIC
VAPORS, OR SOLID PARTICLESFROM THE
TANK.BREATHING THESECONTAMINANTS
CAN CAUSE SERIOUS INJURY OR DEATH.
SPRAYED MATERIALS SUCH AS PAINT, P_JNT
SOLVENI_3, PAINT REMOVER, INSECTICIDES,
WEED KILLERS, MAY CONTAIN HARMFUL
VAPORS AND POISONS.
AIR OBTAINED DIRECTLY FROM THE
COMPRESSORSHOULD NEVER BE USED TO
SUPPLYAIR FOR HUMAN CONSUMPTION. IN
ORDER TO USE AIR PRODUCED BY THIS
COMPRESSOR FOR BREATHING, SUITABLE
FILTERS AND IN-LINE SAFETY EQUIPMENT
MUST BE PROPERLY INSTALLED. IN-LINE
FILTERSAND SAFETY EQUIPMENT USED IN
CONJUNCTION WITH THE COMPRESSOR
MUST BECAPABLEOFTREATING AIR TOALL
APPLICABLE LOCAL AND FEDERAL CODES
PRIORTO HUMAN CONSUMPTION.
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.
5- ENG D24064

HAZARD
RISK OF BURNS
WHAT CAN HAPPEN HOW TO PREVENT IT
TOUCHING EXPOSED METAL SUCH AS THE NEVER TOUCH ANY EXPOSED METAL PARTS
COMPRESSOR HEAD OR OUTLET TUBES, ON COMPRESSOR DURING OR IMMEDIATELY
CAN RESULT IN SERIOUS BURNS. AFTER OPERATION. COMPRESSOR WILL
REMAIN HOT FOR SEVERAL MINUTES AF-I_R
OPERATION,
DO NOT REACH AROUND PROTECTIVE
SHROUDS OR ATrEMPT MAINTENANCE
UNTIL UNIT HAS BEEN ALLOWED TO COOL.
HAZARD
RISK FROM MOVING PARTS I----_ [--_
WHAT CAN HAPPEN
MOVING PARTS SUCH AS THE PULLEY,
FLYWHEEL AND BELT CAN CAUSE SERIOUS
INJURY IF THEY COME INTO CONTACT WII_H
YOU OR YOUR CLOTHING.
HOW TO PREVENT IT
NEVER OPERATE THE COMPRESSOR WITH
GUARDS OR COVERS WHICH ARE DAMAGED
OR REMOVED,
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 CAN
RESULT IN SERIOUS INJURY. HAZARD
ANY REPAIRS REQUIREDON THIS PRODUCT
SHOULD BE PERFORMED BY AUTHORIZED
SERVICECENTER PERSONNEL.
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.
HOW TO PREVENT IT
ALWAYS OPERATE COMPRESSOR IN A
STABLE SECURE POSITION TO PREVENT
ACCIDENTALMOVEMENTOFTHEUNR_ NEVER
OPERATE COMPRESSOR ON A ROOF OR
OTHER ELEVATED POSITION. USE
ADDITIONAL AIR HOSE TO REACH HIGH
LOCATIONS.
HAZARD
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 ALWAYS PLACE COMPRESSOR ON A
RESULT IN FIRE OR BREATHING HAZARD, PROTECTIVE MAT WHEN TRANSPORTING TO
SERIOUS INJURY OR DEATH CAN RESULT PROTECT AGAINST DAMAGE TO VEHICLE
OIL LEAKS WILL DAMAGE CARPE_, PAINT OR FROM LEAKS, REMOVE COMPRESSOR FROM
OTHER SURFACES IN VEHICLES OR VEHICLE IMMEDIATELY UPON ARRIVAL AT
TRAILERS. YOUR DESTINATION.
D24064 6- ENG

HAZARD
RISK OF UNSAFE OPERATION
WHAT CAN HAPPEN
UNSAFEOPERATION OFYOUR AIR
COMPRESSORCOULD LEAD TO SERIOUS IN-
JURY OR DEATH TO YOU OR OTHERS.
HOW TO PREVENT IT
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 AJR
COMPRESSOR AT ALL lIMES.
DO NOT OPERATE THE PRODUCT WREN
FATIGUED OR UNDER THE INFLUENCE OF
ALCOHOL OR DRUGS. STAY ALERT AT ALL
TIMES.
NEVER DEFEAT THE SAFETY FEATURES OF
THIS PRODUCT.
EQUIP AREA OF OPERATION WlTI'I A RRE
EXTINGUISHER.
DO NOT OPERATE MACHINE WITH MISSING,
BROKEN, OR UNAUTHORIZED PARTS.
7- ENG D24064

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.
Cut-In Pressure: While the motor is off, air tank pressure drops as you
continue to use your accessory. When the tank pressure drops to a certain low
level the motor will restart automatically. The low pressure at which the motor
automatically restarts is called "cut-in" pressure.
Cut-Out Pressure: When an air compressor is turned on and begins to run,
air pressure in the air tank begins to build. It builds to a certain high pressure
before the motor automatically shuts off - protecting your air tank from
pressure higher than its capacity. The high pressure at which the motor shuts
off is called "cut-out" pressure.
Branch Circuit: Circuit carrying electricity from electrical panel to outlet.
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. CPLDC2541S
Horsepower Peak 2.5
Bore 2.363"
Stroke .890"
Voltage-Single Phase 120
* * Minimum Branch Circuit Requirement 15 amps
Fuse Type Time Delay
Air Tank Capacity (Gallon) 4.3
Approximate Cut-in Pressure 120 PSIG
Approximate Cut-out Pressure 150 PSIG
SCFM @40 PSIG 5.4
SCFM @ 90 PSIG 4.0
* _ This air compressor can be operated on a 15 amp circuit
if:.
1. Voltage supply to circuitis normal.
2. Circuitis not used to supply anyother electricalneeds (lights,appliances, etc.)
3. Extension cords comply with specificationsin owners manual.
4. Circuit isequipped with 15 amp circuit breakeror 15 amp time daiay fuse,
If any ofthe above conditionscannot be met, or if operation of the aircompressor
repeatedly causes interruptionof the power it may be necessary to operate it from a
20 amp circuit. It is not nec_sary to change the cord set,
* * A cimuitbreaker ispreferred.Use only afuse or circuitbreaker that isthe same
rating as the branch circuiton whichthe air compressor isoperated. If the air
compressor is connected to a circuit protected by fuses, use dual element time
delay fuses.
D24064 8-ENG

ACCESSORIES
Accessories for this unit are available at the store the unit was purchased.
ASSEMBLY
To Add Oil To Pump
_=_f_q_ DO NOT A3"I'EMPT TO OPERATE THIS AIR
COMPRESSOR WITHOUT FIRST ADDING OIL TO 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.
_COMPRESSORS 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 plant testing and does not mean the
pump contains oil.
Multi-Viscosity motor oils, like lOW 30, should not be
used in an air compressor. They leave carbon deposits
on critical components, thus reducing performance and compressor life.
Use air compressor oil only.
NOTE: Use an air compressor oil such as SAE-30 (API CG/CD heavy duty
motor oil). Under extreme winter conditions use SAE-10 weight oil.
1. Place unit on a level surface.
Drain tank to release
air pressure before
removing the dipstick.
_Make sure air vent (B)
in dipstick is free from
debris. If air vent is blocked pressure
can build in crankcase causing damage
to air compressor and possible personal
injury.
2. Remove dipstick (A) and slowly fill
crankcase with oil. C
is 8 fluid ounces (236.6 ml). Oil level
should be at the + (full) mark on the
dipstick.
NOTE= If the oil is added too quickly, it will overflow and appear to be full.
3. Replace dipstick.
9- ENG D24064

INSTALLATION
HOW TO SET UP YOUR UNIT
Location of the Air Compressor
•Locate the air compressor in a clean, dry, and well ventilated area.
•The air compressor should be located at least 12" away from the wall or
other obstructions that will interfere with the flow of air.
•The air filter must be kept clear of obstructions which could reduce air flow
to the air compressor.
• The air compressor requires fresh air flow for proper cooling. DO NOT
ALLOW THE COMPRESSOR TO GET WET.
GROUNDING INSTRUCTIONS
RISK OF ELECTRICAL SHOCK. In the event of a short
circuit, grounding reduces the risk of shock by
providing an escape wire for the electric current, This air compressor
must be properly grounded.
The portable air compressor is equipped with a cord having a grounding wire
with an appropriate grounding plug (see following illustrations),
1, The cord set and plug with this unit contains a grounding pin. This plug
MUST be used with a grounded outlet,
IMPORTANT: The outlet being used must be installed and grounded in
accordance with all local codes and ordinances.
2. Make sure the outlet being used has
the same configuration as the
grounded plug. DO NOT USE AN
ADAPTER. See illustration.
3. Inspect the plug and cord before each
use. Do not use if there are signs of
damage.
4. If these grounding instructions are not
Plug Grounded
Outlets
•.p,
iroun ang irl
completely understood, or if in doubt as to whether the compressor is
properly grounded, have the installation checked by a qualified electrician.
_ _PRc_PER GROUNDING CAN RESULT IN ELECTRICAL
Do not modify the plug provided. If it does not fit the available outlet, a
correct outlet should be installed by a qualified electdcian,
Repairs to the cord set or plug MUST be made by a qualified electrician,
D24064 10-ENG

Extension Cords
Use extra air hose instead of an extension cord to avoid voltage drop and
power loss to the motor, and to prevent overheating.
If an extension cord must be used, be sure it is:
•a 3-wire extension cord that has a3-blade grounding plug, and a 3-slot
receptacle that will accept the plug on the product
•in good condition
•no longer than 50 feet
•12 gauge (AWG) or larger. (Wire size increases as gauge number
decreases. 10 AWG and 8 AWG may also be used. DO NOT USE 14 OR
16 AWG.)
Voltage and Circuit Protection
Refer to the Parts Manual for the voltage and minimum branch circuit
requirements.
Certain air compressors can be operated on a 15 amp circuit if the following
conditions are met.
1. Voltage supply through branch circuit is 15 amps.
2. Circuit is not used to supply any other electrical needs (lights, appliances,
etc.).
3,
4.
Extension cords comply with specifications.
Circuit is equipped with a 15 amp circuit breaker or 15 amp time delay
fuse. NOTE: If compressor is connected to a circuit protected by fuses,
use only time delay fuses. Time delay fuses should be marked "D" in
Canada and "T" in the US.
If any of the above conditions cannot be met, or if operation of the 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.
11- ENG D24064

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.
Description of Operation
Become familiar with these controls before operating the unit.
On/Auto/Off Switch: Turn this switch ON to provide automatic power to the
pressure switch and OFF to remove
power at the end of each use.
Pressure Switch: The pressure switch
automatically starts the motor when the
air tank pressure drops below the saf_ywh,e
factory set "cut-in" pressure. It stops the
motor when the air tank pressure
reaches the factory set "cut-out"
pressure,
Safety Valve: If the pressure switch
does not shut off the air compressor at
its "cut-out" pressure setting, the safety
valve will protect against high pressure
by "popping out" at its factory set pressure (slightly higher than the pressure
switch "cut-out" setting).
Outlet Pressure Gauge: The outlet pressure gauge indicates the air pressure
available at the outlet side of the regulator. This pressure is controlled by the
regulator and is always less than or equal to the tank pressure.
Tank Pressure Gauge: The tank pressure gauge indicates the reserve air
pressure in the tank.
Regulator: 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.
Universal Quick-Connect Body." The universal quick-connect body accepts
the three most popular styles of quick-connect plugs- Industrial, automotive
(Tru-flate), and ARO. One hand push-to-connect operation makes connections
simple and easy.
Drain Valve: The drain valve is located at the
base of the air tank and is used to drain
condensation at the end of each use.
Cooling System (not shown): This compressor
contains an advanced design cooling system. At
the heart of this cooling system is an engineered
fan. It is perfectly normal for this fan to blow air
over the pump head, cylinder sleeve, and crankcase. You know the cooling
system is working when air is being expelled.
Air Compressor Pump (not shown): Compresses air into the air tank.
Working air is not available untilthe compressor has raised the air tank
pressure above that required at the air outlet.
D24064 12-ENG

Dipstick: Indicates the amount of oil in the pump, the +
mark indicates full and the - mark indicates oil needs to
be added. See Oil paragraphs in the Maintenance section
for instructions.
Motor Thermal Overload Protector (not shown): This
motor has a manual thermal overload protector. If the
motor overheats for any reason, the overload protector
will shut off the motor, The motor must be allowed to
cool down before restarting. To restart see the "Motor"
paragraph in the "Maintenance" section.
Air Intake Filter:. This filter is designed to clean air
coming into the pump. This filter must always be clean
and ventilation openings free from obstructions. See
"Maintenance".
Check Valve: When the air compressor is operating,
the check valve is "open", allowing compressed air to
enter the air tank. When the air compressor reaches
"cut-out" pressure, the check valve "closes", allowing air
pressure to remain inside the air tank.
Pressure Release Valve: The pressure release valve
located on the side of the pressure switch, is designed
to automatically release compressed air from the
compressor head and the outlet tube when the air
compressor reaches "cut-out" pressure or is shut off.
The pressure release valve allows the motor to restart
freely. When the motor stops running, air will be heard
escaping from this valve for afew seconds. No air
should be heard leaking when the motor is running, or continuous leaking after
unit reaches "cut-out" pressure.
How to Use Your Unit
How to Stop:
1. Set the On/Auto/Off lever to "OFF".
Before Starting
Break-in Procedure
_Serious damage may result if the following
break-in instructions are not closely followed.
This procedure is required before the air compressor is put into service and
when the check valve or a complete compressor pump has been replaced.
1. Make sure the On/Auto/Off lever is in the "OFF" position.
2. Check oil level in pump. See "Oil" paragraph in the "Maintenance" section
for instructions.
NOTE: Pull coupler back until it clicks to prevent air from escaping through the
quick connect.
13-ENG D24064

3, Plug the power cord into the correct branch circuit receptacle. (Refer to
Voltage and Circuit Protection paragraph in the Installation section of this
manual.)
4. Open the drain valve fully (counter-clockwise) to permit air to escape and
prevent air pressure build up in the air tank during the break-in period.
5. Move the On/Auto/Off lever to "ON/AUTO" position. The compressor will
start.
6. Run the compressor for 20 minutes. Make sure the drain valve is open and
there is minimal air pressure build-up in tank.
7. After 20 minutes, close the drain valve (clockwise). The air receiver will fill
to "cut-out" pressure and the motor will stop.
The compressor is now ready for use.
Before Each Start-Up:
1. Place On/Auto/Off lever to "OFF".
2. Pull regulator knob out, turn counter-clockwise until it stops. Push knob in
to lock in place.
3. Attach hose and accessories. NOTE: The hose or accessory will require a
quick connect plug if the air outlet is equipped with a quick connect
socket.
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.
How to Start:
1. Turn the On/Auto/Off lever to "AUTO" and allow tank pressure to build.
Motor will stop when tank pressure reaches "out-out" pressure.
2. Pull the regulator knob out and turn clockwise to increase pressure. When
the desired pressure is reached push knob in to lock in place. The
compressor is ready for use.
NOTE: Always operate the air compressor in well-ventilated areas free of
gasoline or other combustible vapors. If the compressor is being used to
operate a sprayer DO NOT place near the spray area.
D24064 14- ENG

MAINTENANCE
Customer Responsibilities
Before Daily or Every Every Every Every
each after
each 8 40 160 100 Yearly
use use hours hours hours hours
._heck Safety Valve •
:)rain Tank •
:)il Leaks •
3heck Oil •
3hange Oil
_ir Filter
1- more frequent in dusty or humid conditions
01
_1_ Unit cycles automatically when power is on. When
performing maintenance, you may be exposed to
voltage sources, compressed air, or moving parts. Personal injuries can
occur. Before performing any maintenance or repair, disconnect power
source from the compressor and bleed off all air pressure.
To ensure efficient operation and longer life of the air compressor outfit, a
routine maintenance schedule should be prepared and followed. The following
routine maintenance schedule is geared to an outfit in anormal working
environment operating on adaily basis. If necessary, the schedule should be
modified to suit the conditions under which your compressor is used. The
modifications will depend upon the hours of operation and the working
environment. Compressor outfits 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
_lf the safety valve does not work properly, over-
pressurization 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 operstes freely. If the valve is stuck or does not
operate smoothly, it must be replaced with the same type of valve.
To Drain Tank
1. Set the On/Auto/Off lever to "OFF".
2. Pull the regulator knob out and turn clockwise to set the outlet pressure to
zero.
3. Remove the air tool or accessory.
4. Pull ring on safety valve allowing air to bleed from the tank until tank
pressure is approximately 20 psi. Release safety valve ring.
15- ENG D24064

5. Drain water from air tank by opening drain valve (counter-clockwise) on
bottom of tank. NOTE: Tilt tank forward to drain tank completely.
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.
6. 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.
Oil
Checking
Drain tank to release air pressure before removing the
dipstick or oil drain plug.
Compressor head and cylindersleeve are very hot. Do not
touch.
1. Set the On/Auto/Off lever to "OFF".
2. Remove dipstick (A) and check oil on dipstick for visual signs of
contaminants (water, dirt, etc).
__1=_ Make sure air vent (C)
debds. If air vent is blocked pressure
can build
to air compressor and possible personal
injury.
3. Wipe oil from dipstick.
4. Replace dipstick and allow oil to
collect on dipstick.
5. Remove dipstick and check oil level
on dipstick, + mark indicates full and
the - mark indicates add oil. If oil level
is below - mark, slowly add oil until it
reaches the + (full) mark on the dipstick.
NOTE: Use a air compressor oil such as SAE-30 (API CG/CD heavy duty motor
oil. Under extreme winter conditions use SAE-10 weight oil.
6. Replace dipstick (A).
Changing
1. Set the On/Auto/Off lever to "OFF".
2. Remove the dipstick (A),
3. Remove the oil drain plug (B) and drain oil into a suitable container.
4. Replace the oil drain plug (B).
D24064 16-ENG

NOTE: Use a air compressor oil such as SAE-30 (API CG/CD heavy duty motor
oil Under extreme winter conditions use SAE-10 weight oil.
5. Slowly fill crankcase with oil. Crankcase capacity is 8 fluid ounces (236.6
ml). Oil level should be at the + (full) mark on the dipstick.
_Overfilling with oil will cause premature compressor
failure. Do not overfill.
6. Replace dipstick (A).
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.
Adirty air filter will not allow the compressor to operate at full capacity, Keep
the air filter clean at all times.
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
correct part number,
4. Replace air filter cover and lock into place,
Motor
The motor has an automatic reset thermal overload protector. If the motor
overheats for any reason, the overload protector will shut off the motor. The
motor must be allowed to cool down before restarting. The compressor will
automatically restart after the motor cools.
If the overload protector shuts the motor off frequently, check for apossible
voltage problem, Low voltage can also be suspected when:
1. The motor does not get up to full power or speed.
2, Fuses blow out when starting the motor; lights dim and remain dim when
motor is started and is running.
17-ENG D24064

SERVICE AND ADJUSTMENTS
_Unit cycles automatically when power is on. When doing
Maintenance, you may be exposed to voltage sources,
compressed air or moving parts. Personal injuries can occur. Before performing
any Maintenance or repair, unplug the compressor and bleed off all air
pressure.
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE
PERFORMED BY TRAINED SERVICE TECHNICIAN.
_Before servicing:
•Unplug or disconnect electrical supply to the air compressor.
•Bleed tank of pressure,
•Allow the air compressor to cool,
To Replace or Clean Check Valve
1. Release all air pressure from air tank. See "To Drain Tank" in the
Maintenance section.
2. Unplug outfit.
3. Using an adjustable wrench loosen outlet tube nut at air tank and pump.
Carefully move outlet tube away
from check valve.
4. Using an adjustable wrench loosen
pressure relief tube nut at air tank
and pressure switch. Carefully move
pressure relief tube away from
check valve.
5. Unscrew the check valve (turn
counterclockwise) using a 7/8" open
end wrench. Note the orientation
for reassembly.
6. Unscrew elbow fitting from the
check valve (turn counterclockwise) using an adjustable wrench. Note the
orientation of the elbow fitting for reassembly.
7. Using a screwdriver, carefully push the valve disc up and down. NOTE:
The valve disc should move
freely up and down on a spring
which holds the valve disc in
the closed position, if not the
check valve needs to be
cleaned or replaced. .othlng is visible,
8. Clean or replace the check discisvisible.
valve. A solvent, such as paint
or varnish remover can be used to clean the check valve.
9. Apply sealant to the check valve threads. Reinstall the check valve and
elbow fitting (turn clockwise).
10. Replace the pressure release tube. Tighten nut.
11. Replace the outlet tube and tighten nut.
12. Perform the Break-in Procedure. See "Break-in Procedure" in the
Operation section.
D24064 18- ENG

To Replace Regulator
1, Release all air pressure from air tank. See "To Drain Tank" in the
Maintenance section.
2. Unplug outfit,
3, Using an adjustable wrench remove the gauges and quick connect from
the regulator,
4, Remove the regulator,
5. Apply pipe sealant tape to the nipple on the pressure switch,
6, Assemble the regulator and orient as shown,
NOTE: Arrow indicates flow of air. Make sure it is pointing
in the direction of air flow.
7. Reapply pipe sealant to gauges and quick connect,
8. Reassemble gauges and quick connect. Orient
gauges to read correctly. Tighten quick connect with
wrench.
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. Set the On/Auto/Off 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 air tank by opening drain valve on bottom of tank.
_Watar 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 or drain valve.
NOTE: If drain 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 compressor
handle. (If so equipped)
Store the air compressor in a clean and dry location.
19- ENG D24064

TROUBLESHOOTING
_Pertorming repairs may expose voltage sources, moving
parts or compressed air sources, moving parts or
compressed air sources. Personal injury may occur. Prior to attempting
any repairs, unplug the air compressor and bleed off all air tank air
pressure.
PROBLEM CAUSE CORRECTION
Excessive tank
pressure -
safety valve
pops off,
Air leaks at
fittings.
Air leaks at or
inside check
valve
Air leaks at
pressure switch
release valve.
(if equipped)
Air leaks in air
tank or at air
tank welds.
Air leaks
between head
and valve plate.
Pressure switch does not
shut off motor when
compressor reaches "cut-
out" pressure.
Pressure switch "cut-out"
too high.
Tube fittings are not tight
enough.
Check valve seat damaged.
Defective pressure switch
release valve.
Defective air tank.
Leaking seal.
Move On/Auto/Off lever to
the "OFF" position, if the
outfit does
not shut off contact a
Trained Service Technician.
Contact a Trained Service
Technician.
Tighten fittings where air can
be heard escaping. Check
fittings with soapy water
solution. DO NOT
OVERTIGHTEN.
Adefective check valve
results in a constant air leak
at the pressure release valve
when there is pressure in the
tank and the compressor is
shut off. Replace check
valve. Refer the "To Replace
or Clean Check Valve" in the
"Service and Adjustment"
section.
Contact a Trained Service
Technician,
Air tank must be replaced.
Do not repair the leak.
_Do not
drill into,
weld or otherwise modify
air tank or it will weaken.
The tank can rupture or
explode.
Contact aTrained Service
Technician.
D24064 20- _:NG