Porter-Cable CPLKC7080V2 User manual

Oil Lube Two Stage
Air Compressor
Instruction
manual
IMPORTANT
Please make certain that the person who is
to use this equipment carefully reads and
understands these instructions before
starting operations.
Part No. D22944-049-2
®
ESPAÑOL: PÁGINA 27
FRANÇAIS: PAGE 53
To learn more about Porter-Cable
visit our website at:
http://www.porter-cable.com
Copyright © 2004 Porter-Cable Corporation
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.
CPLKC7080V2

2-ENGD22944
SAFETY GUIDELINES - DEFINITIONS
Indicates an imminent-
ly hazardous situation
which, if not avoided, will result in
death or serious injury.
Indicates a potentially
hazardous situation
which, if not avoided, could result in
death or serious injury.
Indicates a potentially
hazardous situation
which, if not avoided, may result in
minor or moderate injury.
Used without the
safety alert symbol
indicates a potentially hazardous situ-
ation which, if not avoided, may
result in property damage.
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 rec-
ognize this information, we use the symbols below. Please read the manual and pay attention to these
sections.
IMPORTANT SAFETY INSTRUCTIONS
Some dust created by power sanding, sawing, grinding, drilling, and other con-
struction activities contains chemicals known (to the State of California) to cause
cancer, birth defects or other reproductive harm. Some example of these chemicals are:
Glead from lead-based paints
Gcrystalline silica from bricks and cement and other masonry products
Garsenic 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 per-
sonal 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
P.O. Box 2468
Jackson, TN 38302-2468

3-ENG D22944
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 WARN-
INGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT.
RISK OF EXPLOSION OR FIRE
ALWAYS OPERATE THE COMPRESSOR IN A
WELL VENTILATED AREA FREE OF COM-
BUSTIBLE MATERIALS, GASOLINE OR SOL-
VENT 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 COMPRES-
SOR.
NEVER PLACE OBJECTS AGAINST OR ON
TOP OF COMPRESSOR. OPERATE COM-
PRESSOR IN AN OPEN AREA AT LEAST 12
INCHES AWAY FROM ANY WALL OR
OBSTRUCTION THAT WOULD RESTRICT THE
FLOW OF FRESH AIR TO THE VENTILATION
OPENINGS.
OPERATE COMPRESSOR IN A CLEAN, DRY,
WELL VENTILATED AREA. DO NOT OPERATE
UNIT INDOORS OR IN ANY CONFINED AREA.
ALWAYS REMAIN IN ATTENDANCE WITH THE
PRODUCT WHEN IT IS OPERATING.
ALWAYS DISCONNECT ELECTRICAL POWER
BY MOVING PRESSURE SWITCH LEVER TO
THE OFF POSITION AND DRAIN TANK DAILY
OR AFTER EACH USE.
HOW TO PREVENT IT
IT IS NORMAL FOR ELECTRICAL CONTACTS
WITHIN THE MOTOR AND PRESSURE SWITCH
TO SPARK.
IF ELECTRICAL SPARKS FROM COMPRES-
SOR COME INTO CONTACT WITH FLAMMA-
BLE VAPORS, THEY MAY IGNITE, CAUSING
FIRE OR EXPLOSION.
RESTRICTING ANY OF THE COMPRESSOR
VENTILATION OPENINGS WILL CAUSE SERI-
OUS OVERHEATING AND COULD CAUSE
FIRE.
UNATTENDED OPERATION OF THIS PROD-
UCT COULD RESULT IN PERSONAL INJURY
OR PROPERTY DAMAGE. TO REDUCE THE
RISK OF FIRE, DO NOT ALLOW THE COM-
PRESSOR TO OPERATE UNATTENDED.
WHAT CAN HAPPEN
HAZARD

4-ENGD22944
HAZARD
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 PROP-
ERTY DAMAGE OR SERIOUS INJURY.
HOW TO PREVENT IT
WHAT CAN HAPPEN
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.
NEVER DRILL INTO, WELD, OR MAKE ANY
MODIFICATIONS TO THE TANK OR ITS
ATTACHMENTS.
THE TANK IS DESIGNED TO WITHSTAND SPE-
CIFIC 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 EQUIP-
MENT MANUFACTURERS RECOMMENDATION
AND NEVER EXCEED THE MAXIMUM ALLOW-
ABLE PRESSURE RATING OF ATTACHMENTS.
NEVER USE COMPRESSOR TO INFLATE
SMALL LOW-PRESSURE OBJECTS SUCH AS
CHILDREN’S TOYS, FOOTBALLS, BASKET-
BALLS, ETC.
1. FAILURE TO PROPERLY DRAIN CON-
DENSED WATER FROM THE TANK,
CAUSING RUST AND THINNING OF
THE STEEL TANK.
2. MODIFICATIONS OR ATTEMPTED
REPAIRS TO THE TANK.
3. UNAUTHORIZED MODIFICATIONS TO
THE UNLOADER VALVE, SAFETY
VALVE, OR ANY OTHER COMPONENTS
WHICH CONTROL TANK PRESSURE.
4. EXCESSIVE VIBRATION CAN WEAKEN
THE AIR TANK AND CAUSE RUPTURE
OR EXPLOSION.
ATTACHMENTS & ACCESSORIES:
EXCEEDING THE PRESSURE RATING OF AIR
TOOLS, SPRAY GUNS, AIR OPERATED
ACCESSORIES, TIRES AND OTHER INFLATA-
BLES CAN CAUSE THEM TO EXPLODE OR
FLY APART, AND COULD RESULT IN SERIOUS
INJURY.
HAZARD
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, RESULTING IN PROPERTY DAMAGE
OR PERSONAL INJURY.
ALWAYS WEAR ANSI Z87.1 APPROVED SAFE-
TY 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.

5-ENG D22944
HAZARD
HAZARD
HOW TO PREVENT IT
WHAT CAN HAPPEN
RISK TO BREATHING
AIR OBTAINED DIRECTLY FROM THE COM-
PRESSOR SHOULD NEVER BE USED TO
SUPPLY AIR 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
FILTERS AND SAFETY EQUIPMENT USED IN
CONJUNCTION WITH THE COMPRESSOR
MUST BE CAPABLE OF TREATING AIR TO
ALL APPLICABLE LOCAL AND FEDERAL
CODES PRIOR TO 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.
THE COMPRESSED AIR DIRECTLY FROM
YOUR COMPRESSOR IS NOT SAFE FOR
BREATHING. THE AIR STREAM MAY CON-
TAIN CARBON MONOXIDE, TOXIC VAPORS,
OR SOLID PARTICLES FROM THE TANK.
BREATHING THESE CONTAMINANTS CAN
CAUSE SERIOUS INJURY OR DEATH.
SPRAYED MATERIALS SUCH AS PAINT, PAINT
SOLVENTS, PAINT REMOVER, INSECTICIDES,
WEED KILLERS, MAY CONTAIN HARMFUL
VAPORS AND POISONS.
RISK OF ELECTRICAL SHOCK
HOW TO PREVENT IT
WHAT CAN HAPPEN
YOUR AIR COMPRESSOR IS POWERED BY
ELECTRICITY. LIKE ANY OTHER ELECTRI-
CALLY POWERED DEVICE, IF IT IS NOT USED
PROPERLY IT MAY CAUSE ELECTRIC
SHOCK.
REPAIRS ATTEMPTED BY UNQUALIFIED PER-
SONNEL 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.
SEE GROUNDING INSTRUCTIONS.
NEVER OPERATE THE COMPRESSOR OUT-
DOORS WHEN IT IS RAINING OR IN WET CON-
DITIONS.
NEVER OPERATE COMPRESSOR WITH PRO-
TECTIVE COVERS 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 CIR-
CUIT TO WHICH THE COMPRESSOR IS CON-
NECTED PROVIDES PROPER ELECTRICAL
GROUNDING, CORRECT VOLTAGE AND ADE-
QUATE FUSE PROTECTION.

6-ENGD22944 6-ENG
HAZARD
HOW TO PREVENT IT
WHAT CAN HAPPEN
RISK OF BURNS
TOUCHING EXPOSED METAL SUCH AS THE
COMPRESSOR HEAD OR OUTLET TUBES,
CAN RESULT IN SERIOUS BURNS.
NEVER TOUCH ANY EXPOSED METAL
PARTS ON COMPRESSOR DURING OR IMME-
DIATELY 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.
HAZARD
HOW TO PREVENT IT
WHAT CAN HAPPEN
RISK FROM MOVING PARTS
NEVER OPERATE THE COMPRESSOR WITH
GUARDS OR COVERS WHICH ARE DAMAGED
OR REMOVED.
ANY REPAIRS REQUIRED ON THIS PRODUCT
SHOULD BE PERFORMED BY AUTHORIZED
SERVICE CENTER PERSONNEL.
MOVING PARTS SUCH AS THE PULLEY, FLY-
WHEEL AND BELT CAN CAUSE SERIOUS
INJURY IF THEY COME INTO CONTACT WITH
YOU OR YOUR CLOTHING.
ATTEMPTING TO OPERATE COMPRESSOR
WITH DAMAGED OR MISSING PARTS OR
ATTEMPTING TO REPAIR COMPRESSOR
WITH PROTECTIVE SHROUDS REMOVED CAN
EXPOSE YOU TO MOVING PARTS AND CAN
RESULT IN SERIOUS INJURY.
HAZARD
HOW TO PREVENT IT
WHAT CAN HAPPEN
HAZARD
HOW TO PREVENT IT
WHAT CAN HAPPEN
RISK OF FALLING
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.
ALWAYS OPERATE COMPRESSOR IN A STA-
BLE SECURE POSITION TO PREVENT ACCI-
DENTAL MOVEMENT OF THE UNIT. NEVER
OPERATE COMPRESSOR ON A ROOF OR
OTHER ELEVATED POSITION. USE ADDI-
TIONAL AIR HOSE TO REACH HIGH LOCA-
TIONS.
RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR
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 TRAIL-
ERS.
ALWAYS PLACE COMPRESSOR ON A PRO-
TECTIVE MAT WHEN TRANSPORTING TO
PROTECT AGAINST DAMAGE TO VEHICLE
FROM LEAKS. REMOVE COMPRESSOR FROM
VEHICLE IMMEDIATELY UPON ARRIVAL AT
YOUR DESTINATION.
(Fire, Inhalation, Damage to Vehicle Surfaces)

7-ENG D22944D22944
HAZARD
HOW TO PREVENT IT
WHAT CAN HAPPEN
RISK OF UNSAFE OPERATION
REVIEW AND UNDERSTAND ALL INSTRUC-
TIONS AND WARNINGS IN THIS MANUAL.
BECOME FAMILIAR WITH THE OPERATION
AND CONTROLS OF THE AIR COMPRESSOR.
KEEP OPERATING AREA CLEAR OF ALL PER-
SONS, PETS, AND OBSTACLES.
KEEP CHILDREN AWAY FROM THE AIR COM-
PRESSOR AT ALL TIMES.
DO NOT OPERATE THE PRODUCT WHEN
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 WITH A FIRE
EXTINGUISHER.
DO NOT OPERATE MACHINE WITH MISSING,
BROKEN, OR UNAUTHORIZED PARTS.
UNSAFE OPERATION OF YOUR AIR COM-
PRESSOR COULD LEAD TO SERIOUS INJURY
OR DEATH TO YOU OR OTHERS.

8-ENGD22944
Model No. CPLKC7080V2
Horsepower Peak 7.0
Voltage-Single Phase 240V/60Hz/1Ph
Minimum Branch Circuit Requirement 30 amps
*Fuse Type Time Delay
Air Tank Capacity, Gallons 80 ASME, Vertical
Approximate Cut-in Pressure 140 PSIG
Approximate Cut-out Pressure 175 PSIG
SCFM @ 100 psig 17.3
SCFM @ 175 psig 16.8
SPECIFICATIONS
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 deliv-
ery.
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
DUTY CYCLE
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
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 auto-
matically 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 elec-
tricity from electrical panel to outlet.
To Lock Out Power: Place a lock on
the line power switch so no one else
can turn on the power.
hour is considered misuse, because
the air compressor is undersized for
the required air demand. Maximum
compressor pumping time per hour is
30 minutes.
Accessories for this unit are available at the store the unit was purchased.
ACCESSORIES
* A circuit breaker is preferred. Use only a fuse or circuit breaker that is the same
rating as the branch circuit on which the air compressor is operated. If compres-
sor 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.

9-ENG D229449-ENG D229449-ENG
2. Obtain the drain plug extension
(D), from the parts bag.
3. Apply thread sealant tape to the
threads of the drain plug exten-
sion (D).
4. Assemble the washer (C), drain
plug extension (D), and drain
plug (B) as shown in Figure.
5. Tighten securely.
6. Remove the oil fill plug (A.
7. Fill the crankcase with the rec-
ommended oil. NOTE: Use an air
compressor oil such as SAE-30
(API CG/CD heavy duty motor
oil). Under extreme winter condi-
tions use SAE-20 weight oil.
8. Replace the oil fill plug (A) and
tighten securely.
A
C
B
ASSEMBLY
Tools Required for Assembly
1 - 9/16" socket or open end wrench
1 - electric drill
Unpacking
1. Remove all packaging.
It may be neces-
sary to brace or
support one side of the outfit
when removing the pallet because
the air compressor will have a
tendency to tip.
2. Remove and discard the (4)
screws and washers holding the
compressor to the pallet.
3. With the help of another person
carefully remove air compressor
from pallet and place on a level
surface.
To Add Oil To Pump
Compressors are
shipped without oil.
A small amount of oil may be pres-
ent in the pump upon receipt of the
air compressor. This is due to plant
testing and does not mean the
pump contains oil. Do not attempt
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 fol-
low initial start-up procedures.
Multi-Viscosity
motor oils, like
10W 30, should not be used in an
air compressor. They leave carbon
deposits on critical components,
thus reducing performance and
compressor life. Use air compres-
sor oil only.
1. Remove the oil drain plug (B) and
washer (C).
CDB
9-ENG

10-ENGD22944
1. Place the air compressor on on a
solid, level surface.
2. Mark the surface using the holes
in the air compressor feet as a
template.
3. Drill holes in the surface for the
concrete anchors. Install con-
crete anchors.
4. Line-up holes in surface with
holes in air compressor feet.
5. Place the (4) washers (not sup-
plied) between the floor and air
compressor feet. If needed, solid
shims may be placed between
the washers and floor to evenly
distribute weight on all four feet.
See next figure.
6. Place the (4) 3/8" lag screws
through the air compressor feet,
washers, shims, and into the
anchors.
7. Torque 3/8" lag screws to 7-10
ft.-lbs.
Anchoring of the Air
Compressor
Excessive Vibration
can weaken the air
tank and cause an explosion. The
compressor must be properly
mounted.
The air compressor MUST be bolted
to a solid, level surface.
Hardware needed:
4 - Concrete anchors (not sup-
plied)
4 - 3/8" Lag screw to fit con-
crete anchors (not supplied)
4 - 5/8" Washer (not supplied)
- Shims (if needed)
Location of the Air Compressor
• Locate the air compressor in a
clean, dry, and well ventilated
area.
• Locate the air compressor at
least 12" away from the wall or
other obstructions that will inter-
fere with the flow of air.
• Locate the air compressor as
close to the main power supply
as possible to avoid using long
lengths of electrical wiring.
NOTE: Long lengths of electrical
wiring could cause power loss to
the motor.
• The air filter must be kept clear
of obstructions which could
reduce air flow to the air com-
pressor.
HOW TO SET UP YOUR UNIT
3/8" Lag
Screw
(not supplied)
5/8" Washer
(not supplied)
Shim Under
Washer
(not supplied)
Concrete Anchor
(not supplied)
Surface Line
INSTALLATION

11-ENG D22944
GROUNDING INSTRUCTIONS
This product should be connected to
a metallic, permanent wiring system,
or an equipment-grounding terminal
or lead on the product and comply
with national and local electrical
codes.
Refer to the product specification
found in the front of this manual for
the voltage and minimum branch cir-
cuit requirements.
Air Distribution System
Plastic or PVC pipe
is not designed for
use with compressed air.
Regardless of its indicated pres-
sure rating, plastic pipe can burst
from air pressure. Use only metal
pipe for air distribution lines.
The next figure represents a typical
air distribution system. The following
are tips to remember when setting up
the air compressor’s air distribution
system.
Wiring Instructions
RISK OF ELECTRI-
CAL SHOCK.
Improper electrical grounding can
result in electrical shock. The
wiring should be done by a quali-
fied electrician to comply with
national and local electrical codes.
A qualified electrician needs to knows
the following before wiring:
1. The amperage rating of the elec-
trical box should be adequate.
Refer to the product specifica-
tions, found in the front of this
manual, for this information.
2. The supply line should have the
same electrical characteristics
(voltage, cycle, phase) as the
motor. Refer to the motor name-
plate, on side of motor, for this
information.
NOTE: The wiring must be the same
as the motor nameplate voltage plus
or minus 10%. Refer to local codes
for recommended wire sizes, correct
wire size, and maximum wire run;
undersize wire causes high amp draw
and overheating to the motor.
Electrical wiring
must be located
away from hot surfaces such as
manifold assembly, compressor
outlet tubes, heads, or cylinders.

12-ENGD22944
• 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. Fill lines with air pres-
sure before covering to make
sure pipe joints are free from
leaks.
• Install a flexible coupling
between the air discharge outlet
and main air distribution line to
allow for vibration.
NOTE: The shut-off valve is not sup-
plied with this unit. You must purch-
sase the shut-off valve separately.
• A separate regulator is recom-
mended to control the air pres-
sure. Air pressure from the air
tank is usually too high for indi-
vidual air driven tools.
DRAIN
TRAP
DRAIN
TRAPS
DRAIN
LEGS
MOISTURE
SEPARATOR
AND TRAP
DIRT
LEG
DIRT
LEG
LUBRICATOR
REGULATOR
FILTER
AIR DISCHARGE
VALVE
LUBRICATOR
MAIN DISTRIBUTION AIR LINES
Slope pipe in direction of air flow.
Water condensate flows along
bottom of pipe to drain legs,
preventing it from entering feeder
lines.
REGULATOR
FLEXIBLE
COUPLING
DRAIN COCK
VALVE
TYPICAL COMPRESSED
AIR DISTRIBUTION SYSTEM
AIR FLOW AIR FLOW
FEEDER LINES SLOPE
WITH AIR FLOW
AIR USAGE
LINES
AIR
COMPRESSOR

13-ENG D22944D22944
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 factory set "cut-in" pres-
sure. 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).
Tank Pressure Gauge: The tank pressure gauge indicates the reserve air
pressure in the tank.
Globe Valve (sold separately): Opens and closes air discharge valve. Turn
knob counter-clockwise to open and clockwise to close.
Regulator (sold separately, not shown): An air pressure regulator or a sepa-
rate air transformer which combines the functions of air regulation and/or mois-
ture and dirt removal is recommended for most applications.
Drain Valve: The drain valve is located at the
base of the air tank and is used to drain conden-
sation 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 through the vent holes in large
amounts. You know that the cooling system is working when air is being
expelled.
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.
Globe Valve
Tank
Pressure
Gauge
Safety Valve
On/Auto/Off
Switch
Pressure
Switch
Drain
Valve

14-ENGD22944 14-ENG
Air Compressor Pump (not shown): Compresses
air into the air tank. Working air is not available until
the compressor has raised the air tank pressure
above that required at the air outlet.
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 a few seconds. No air should be heard leaking when the motor is
running, or continuous leaking after unit reaches "cut-out" pressure.
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
obstructions. See "Maintenance".
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. Recheck all wiring. Make sure wires are secure at all terminals connections.
Make sure all contacts move freely and are not obstructed.
3. Open the globe valve fully to permit air to escape and prevent air pressure
build up in the air tank during the break-in period. NOTE: The shut-off
valve is not supplied with this unit. You must purchase the shut-off
valve separately.
4. Move the On/Auto/Off lever to "ON/AUTO" position. The compressor will
start.
5. Run the compressor for 20 minutes. Make sure the globe valve is open
and there is minimal air pressure build-up in tank.
How to Use Your Unit
How to Stop:
1. Set the On/Auto/Off lever to "OFF".
Check Valve
Pressure
Release
Valve

15-ENG D22944
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 "cut-out" pressure.
2. When the tank pressure reaches "cut-out" pressure open the globe valve.
IMPORTANT: When using regulator and other accessories refer to the manu-
facturer-s instructions.
NOTE: Always operate the air compressor in well-ventilated areas free of gaso-
line or other combustible vapors. If the compressor is being used to operate a
sprayer, DO NOT place compressor near the spray area.
Before Each Start-Up:
1. Place On/Auto/Off lever to "OFF".
2. Close the globe valve.
3. Attach hose and accessories. NOTE: A regulator MUST be installed when
using accessories rated at less than 175 PSI.
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.
6. Check all air line fittings and connections/piping for air leaks by applying a
soap solution. Correct if necessary. NOTE: Minor leaks can cause the air
compressor to overwork, resulting in premature breakdown or inadequate
performance.
7. Check for excessive vibration. Readjust or shim air compressor feet, if
necessary.
8. After 20 minutes, close the globe valve. The air receiver will fill to "cut-out"
pressure and the motor will stop.

16-ENGD22944 16-ENG
MAINTENANCE
Customer Responsibilities
Before
each
use
●
●
●2
Every
8
hours
Every
40
hours
Every
100
hours
Yearly
Every
160
hours
●
●1
1- more frequent in dusty or humid conditions
2- more frequent if humidity or operating conditions are extreme.
Check Safety Valve
Drain Tank
Check Oil
Change Oil
Air Filter
NOTE: See "Operation" section for the location of controls.
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 outfits in an extremely dirty and/or hostile environment will require
a greater frequency of all maintenance checks.
Unit cycles automatically when power is on. When per-
forming 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 Check Safety Valve
If the safety valve
does not work prop-
erly, over-pressurization may occur,
causing air tank rupture or an
explosion.
Unusual Noise and/or
Vibration
Drive Belt-Condition
Motor Pulley/Flywheel alignment
Air compressor pump intake
and exhaust valves
Inspect air lines and fittings
for leaks
●2
●
●
●
●
●
Head Bolts - Check the torques of the head bolts after the first five hours of operation.
Every
500
hours
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 operate
smoothly, it must be replaced
with the same type of valve.

17-ENG D22944D22944
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. Sowly add compressor oil until
the oil level is in the middle of the
sightglass (C). NOTE: When fill-
ing the crankcase, the oil flows
very slowly into the pump. If the
oil is added too quickly, it will
overflow and appear to be full.
Overfilling with oil
will cause prema-
ture compressor failure. Do not
overfill.
5. Replace oil fill plug (A) and tight-
en securely.
Oil
NOTE: Use a air compressor oil such
as SAE-30 (API CG/CD heavy duty
motor oil). Under extreme winter con-
ditions use SAE-20 weight oil. NOTE:
Crankcase oil capacity is approxi-
mately 60 fluid ounces (1.8 L).
Checking
1. The oil level should be to the mid-
dle of the sight glass (C).
2. If needed remove oil fill plug (A)
and slowly add oil until it reaches
the middle of the sight glass.
To Drain Tank
NOTE: Operation of the air compres-
sor will cause condensation to build
up in the air tank. Always drain tank
on a washable surface or in a suit-
able container to prevent damaging
or staining surfaces.
1. Set the On/Auto/Off lever to
"OFF".
2. Close the globe valve.
3. Remove the air tool or
accessory.
4. Open the globe valve and allow
the air to slowly bleed from the
air tank until tank pressure is
approximately 20 psi.
5. Close the globe valve.
6. Drain water from air tank by
opening drain valve (counter-
clockwise) on bottom of tank.
Water will con-
dense in the air
tank. If not drained, water will cor-
rode and weaken the air tank
causing a risk of air tank rupture.
7. 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.
B
A
C
C

18-ENGD22944
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.
A dirty air filter will not allow the
compressor to operate at full capaci-
ty. 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.
Adjusting Belt Tension
1. Slide motor into original position,
line the motor up with the mark
made earlier on saddle.
2. Tighten two outside motor
mounting screws enough to hold
the motor in place for checking
pulley and flywheel alignment.
3. The belt should deflect 3/16" at
midway between the pulley and
the flywheel when a 5 pound
weight is applied at the midway
point.
4. When proper belt tension is
achieved, tighten all four motor
mounting screws. See Parts
manual for torque specifications.
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.
Belt - Replacement
(Refer to the Outfit Parts Manual
for replacement belt part number.)
Serious injury or
damage may
occur if parts of the body or loose
items get caught in moving parts.
Never operate the outfit with the
belt guard removed. The belt
guard should be removed only
when the AIR compressor power
is disconnected.
1. Turn air compressor off, lock
out the power supply, and
relieve all air pressure from the
air tank.
2. Remove the belt guard.
3. Mark pump position on saddle.
4. Loosen the motor mounting
screws and slide the motor
toward the air compressor.
5. Remove the belt and replace
with a new one.
Downward Force
Deflection
6. See the "Adjust Belt Tension"
before tightening motor mount-
ing screws.

19-ENG D22944
Air Compressor Pump Intake
and Exhaust Valves
Once a year have a Trained Service
Technician check the air compressor
pump intake and exhaust valves.
Inspect Air Lines and Fittings
for Leaks
1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Apply a soap solution to all air
line fittings and connections/pip-
ing.
3. Correct any leaks found.
IMPORTANT: Even minor leaks can
cause the air compressor to over-
work, resulting in premature break-
down or inadequate performance.
Motor Pulley/Flywheel
Alignment
NOTE: Once the motor 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.
The air compressor flywheel and
motor pulley must be in-line (in the
same plane) within 1/16" to assure
belt retention within flywheel belt
grooves. To check alignment, per-
form the following steps:
1. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
2. Remove belt guard.
3. Place a straightedge against the
outside of the flywheel and the
motor 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 set screw
holding the motor 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 motor drive pulley
set screw. See Parts manual for
torque specifications.
Air compressor Head Bolts -
Torquing
The air compressor pump head bolts
should be kept properly torqued.
Check the torques of the head bolts
after the first five hours of operation.
Retighten if necessary. See Parts
manual for torque specifications.
7. Visually inspect the motor drive
pulley to verify that it is perpen-
dicular 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 motor drive pulley and
equalize B1 and B2, using care
not to disturb the belt alignment
performed in step 2.
8. Retighten the motor drive pulley
setscrew. See Parts manual for
torque specifications.
9. Reinstall belt guard.

20-ENGD22944
SERVICE AND ADJUSTMENTS
Unit cycles automat-
ically 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. Turn air compressor off, lock out
the power supply, and relieve all
air pressure from the air tank.
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. 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.
7. Clean or replace the check valve.
A solvent, such as paint or
varnish remover can be used to
clean the check valve.
8. Apply sealant to the check valve
threads. Reinstall the check valve
(turn clockwise).
9. Replace the pressure release
tube. Tighten nuts.
10. Replace the outlet tube and
tighten nuts.
11. Perform the Break-in Procedure.
See "Break-in Procedure" in the
Operation section.
In closed position
disc is visible.
In open
position
nothing is
visible.
Screwdriver