Craftsman 919165580 Owner’s Manual

Owner's Manual
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Permanently Lubricated Single Stage
Portable
AIR COMPRESSOR
Model No.
919.165580
Assembly
Operation
Maintenance
Service and Adjustments
Troubleshooting
Repair Parts
CAUTION: Read the Safety Guidelines and All Instructions Carefully Before
Operating.
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Visit our Craftsman website: www.sears.com/craftsman
A00854 Rev. 0 12/07/03
WARRANTY ................................................ 2
SPECIFICATION CHART ..................................... 3
SAFETY GUIDELINES ...................................... 3-8
GLOSSARY ................................................ 9
ACCESSORIES ............................................. 9
DUTY CYCLE .............................................. 9
ASSEMBLY ............................................... 10
INSTALLATION .......................................... 11-12
OPERATION ............................................ 13-15
MAINTENANCE ......................................... 16-17
SERVICE AND ADJUSTMENTS ............................ 18-19
STORAGE ................................................ 20
TROUBLESHOOTING GUIDE .............................. 21-23
REPAIR PARTS ......................................... 24-27
ESPAI_IOL .............................................. 28-49
NOTES/NOTAS ............................................ 50
REPAIR PROTECTION AGREEMENTS ......................... 51
HOW TO ORDER REPAIR PARTS ...................... back cover
FULL ONE YEAR WARRANTY AIR COMPRESSOR
If this CRAFTSMAN Air Compressor fails due to a defect in material or workmanship within one year from the date of purchase, Sears will at its option repair or replace it free of charge. Contact your nearest Sears Service Center (1-800-4-MY-HOME ®)to arrange for repair, or return the Air
Compressor to the place of purchase for replacement.
If this Air Compressor is used for commercial or rental purposes, this warrant applies for only ninety days from the date of purchase.
This warranty gives you specific legal rights and you may have other rights which vary from state to state.
Sears, Roebuck and Co., Dept. 817WA, Hoffman Estates, IL 60179
A00854 2* ENG
Model No. 919.165580
Max. Developed HP 5.0 Running HP 1.7 Bore 2.375" Stroke 1.35"
Voltage-Single Phase 120V/60HZ Minimum Branch Circuit Requirement 15 amps
Fuse Type Time Delay Air Tank Capacity 33
Approx. Cut-In 120 Approx. Cut-out 150 SCFM @40 psig 7.8
SCFM @ 90 psig 5.8
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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 symbols.
_"_"_r_ Indicat es an
imminently hazardous
situation which, if not avoided, will
result in death or serious iniury.
_1 Indicates a
potentially hazardous
situation which, if not avoided, result in minor or moderate inju W.
_lndicates a
potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
_Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities contains chemicals
_Used without the
safety alert symbol indicates a potentially hazardous situation which, if not avoided, may
result in DroDertv damaae.
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.
3* ENG A00854
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Save these instructions
Improper operation or maintenance of this product could result in serious injury and property damage. Read and understand all warnings and operation instructions before using this equipment.
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WARNING: Risk of explosion or fire
What Could Happen
tt 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.
Unattended operation of this product
could result in personal injury or
property damage. To reduce the risk of
fire, do not allow the compressor to operate unattended.
How To Prevent It
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 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,
A00854 4* ENG
WARNING: Risk of Bursting
Air Tank: The following conditions could lead to a weakening of the tank, and result
in a violent tank explosion and could cause property damage or serious injury.
f.
Failure to properly drain
condensed water from tank, causing rust and thinning of the
steel tank.
What Could Happen
2.
Modifications or attempted repairs to the tank.
3.
Unauthorized modifications to the
Drain tank daily or after each use. If
tank 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.
HOw To Prevent It
unloader valve, safety valve, or any other components which control
tank pressure. Excessive vibration can weaken
4. The tank is designed to withstand specific
the air tank and cause rupture or explosion
operating pressures. Never make adjustments or parts substitutions to
alter the factory set operating
pressures.
ATTACHMENTS & ACCESSORIES:
Exceeding the pressure rating of air
tools, spray guns, air operated accessories, tires, and other inflatables
can cause them to explode or fly apart, and could result in serious injury.
For essential control of air pressure, you must install a pressure regulator and
pressure gauge to the air outlet (if not equipped) of your compressor. Follow the
equipment manufacturers recommendation and never exceed the
maximum allowable pressure rating of attachments. Never use compressor to
inflate small low pressure objects such as children's toys, footballs, basketballs, etc.
WARNING: Risk from Flying Objects
WHATCAN 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.
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Always wear ANSI Z87.f 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 end
bleed pressure from the air hose and tank before attempting maintenance, attaching
tools or accessories.
5* ENG A00854
WARNING: 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 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.
WARNING: Risk to Breathing
WHAT CAN HAPPEN
The compressed air directly from your compressor is not safe for breathing
The air stream may contain carbon
monoxide, toxic vapors, or solid particles from the tank. Breathing these
contaminants can cause serious injury or death.
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 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,
,I;1"1'.I;1=
HOW TO PREVENT IT
Air obtained directly from the compressor should never be used to supply air for
human consumption, In order to use air
produced by this compressor for 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.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides, weed killers, may contain harmful vapors
and poisons.
A00854 6* ENG
Work in an area with good cross ventilation. Read and follow the safety
instructions provided on the label or safety data sheets for the materials you
are spraying, Use a NtOSH/MSHA approved respirator designed for use
with your specific application.
WARNING: RISK OF BURNS
WHAT CAN HAPPEN
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 immediately
after operation. Compressor will remain hot for several minutes after operation.
Do not reach around protective shrouds or attempt maintenance until unit has
been allowed to cool.
HOW TO PREVENT IT
,{.4"4.,I"! =
WARNING: RISK FROM MOVING PARTS
WHAT CAN HAPPEN
Moving parts such as the pulley, flywheel,
and belt can cause serious injury if they come into contact with you or your clothing.
Attempting to operate compressor with Any repairs required on this product damaged or missing parts or attempting should be performed by authorized
to repair compressor with protective service center personnel. shrouds removed can expose you to moving parts and can result in serious injury.
Never operate the compressor with
guards or covers which are damaged or removed.
HOW TO PREVENT IT
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WARNING: Risk of Falling
What Could Happen How To Prevent It
A portable compressor can fall from a Always 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, position. Use additional air hose to
reach high locations.
ENG A00854
WARNING: RISK OF SERIOUS INJURY OR PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR
(Fire, Inhalation, Damage to Vehicle Surfaces)
WHAT CAN HAPPEN
Oil can leak or spill and could result in fire or breathing hazard; serious injury or
death can result. Oil leaks will damage carpet, paint or other surfaces in vehicles
or trailers.
Always place compressor on e
protective mat when transporting to protect against damage to vehicle from
leaks. Remove compressor from vehicle immediately upon arrival at your destination.
HOW TO PREVENT IT
,1:1"1'.111=
WARNING: RISK OF UNSAFE OPERATION
WHAT CAN HAPPEN
Unsafe operation of your air compressor could lead to serious injury or death to you or others.
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,
_ets, and obstacles.
Keep children away from the air compressor 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
_roduct.
Equip area of operation with a fire extinguisher. DO not operate machine with missing,
broken, or unauthorized parts.
HOW TO PREVENT IT
A00854 8* ENG
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.
PSlG: 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.
This unit is capable of powering the following Accessories. The accessories are available through the current Power and Hand Tool Catalog or full-line Sears
stores.
Accessories Oil Fog Lubricators
In Line Filter Air Hose: 1/4", 3/8" or 1/2" I.D. in
Tire Air Chuck various lengths
Quick Connector Sets (various Refer to the selection chart located sizes) on the unit to select the tools this unit
Air Pressure Regulators is capable of powering.
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This air compressor pump is capable
of running continuously. However, to prolong the life of your air compressor, it is recommended that
a 50%-75% average duty cycle be
maintained; that is, the air
compressor pump should not run
more than 30-45 minutes in any
given hour.
9- ENG A00854
Contents of Carton
1 - Air Compressor 1- Handle
4 - Self Tapping Screw 2- Wheels
2 - Shoulder Bolts, 3/8 2- Hex Nuts, 3/8 1 - Rubber Strip
Tools Required for Assembly
1 - 9/16" socket or open end wrench 1 - 1/2" socket or open end wrench
Unpacking
1. Remove unit from carton and discard all packaging. NOTE:
Save all parts bags.
Assemble Handle
1. Insert the handle inside the compressor saddle and line up
the two bolt holes on each side.
2. Install the four screws, two on each side.
3. Tighten securely.
Assemble Wheels
It will be
necessary to brace or support one side of the unit when installing the wheels because the compressor will have a tendency to tip.
1. Attach wheels with shoulder bolts and nuts as shown.
2. Tighten securely. NOTE: The unit will sit level if the wheels are
properly installed.
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.
Assemble Rubber Strip
1. Clean and dry underside of air tank leg opposite wheels.
2. Remove the protective paper strip from the adhesive backed rubber foot strip.
3. Attach the rubber foot strip to the bottom of leg. Press firmly
into place.
Scl_w
Shoulder
Wheel Bolt
Rubber Strip
A00854 10_ ENG
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 compressor
pump and shroud are designed to allow for proper cooling. The ventilation openings on the compressor are necessary to maintain proper operating temperature. Do not place rags or
other containers on or near these openings. The air filter must be kept
clear of obstructions which could reduce air flow to the air compressor.
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). The plug must be used
with an outlet that has been installed and grounded in accordance with all
local codes and ordinances.
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.
l1_lU_F_g _Grounded
_ _Outlets
Grou_d_ing Pin
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 completely understood, or if in doubt as to whether the
compressor is properly grounded, have the installation checked by a qualified
electrician.
I_'_'_ Risk of Electrical
Shock. Improper
grounding can result in electrical shock.
Do not modify the plug provided. If it does not fit the available outlet, a
correct outlet should be installed by a qualified electrician.
Repairs to the cord set or plug MUST be made by a qualified
electrician.
11_ ENG A00854
Extension Cords
Using extension cords is not recommended. The use of extension
cords will cause voltage to drop resulting in power loss to the motor
and overheating. Instead of using an extension cord,
increase the working reach of the air hose by attaching
If an extension cord must be used, be sure it is:
a 3-wire extension cord that has a 3-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.
Risk of Unsafe Operation. Certain
air compressors can be operated on a 15 amp circuit if the following conditions are met.
1. Voltage supply to circuit must comply with the National
Electrical Code.
2.
Circuit is not used to supply any other electrical needs.
3.
Extension cords comply with
specifications.
4.
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.
A00854 12- ENG
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 vanous controls and adjustments. Save this manua[for future reference.
Description of Operation
Become familiar with these controls before operating the unit.
Regulator
On/Auto/Off Switch: Turn this
switch "ON/AUTO" 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" 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.
Drain Valve:
The drain valve is located at
the base of the air tank and is Valve
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 through the vent holes in large amounts. You know that 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 until the compressor has raised the air tank pressure above that required at the
air outlet.
13_ ENG A00854
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, Release
Pressure
located on Valve 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".
Motor Overload Protector: 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.
How to Use Your Unit
How to Stop:
1. Set the On/Auto/Off lever to
"OFF".
Before First Start Up:
Risk of Unsafe
Operation. 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.
NOTE: If quick connect is installed, pull coupler back until it clicks to prevent air from escaping through the quick connect.
2.
Plug the power cord into the correct branch circuit receptacle. (Refer to Voltage and Circuit
Protection paragraph in the
Installation section of this manual.)
A00854 14_ ENG
3. 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.
NOTE: Always drain tank on a washable surface or in a suitable
container to prevent damaging or staining surfaces.
4.
Move the On/Auto/Off lever to "ON/AUTO" position. The
compressor will start.
5.
Run the compressor for 15 minutes. Make sure the drain
valve is open and there is minimal air pressure build-up in
tank.
6. After 15 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.
How to Start:
1. Turn the On/Auto/Off lever to "ON/AUTO" and allow tank
pressure to build. Motor will stop when tank pressure reaches
"cut-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.
Risk of Bursting.
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.
15_ ENG A00854
Customer Responsibilities
Before Daily ol
after Every Every
aach each 40 100 Yearly use use hours "_ours
Check Safety Valve Drain Tank
Air Filter •(1) Air compressor pump intake
and exhaust valves
1- more frequent in dusty or humid conditions
Risk of Unsafe
Operation. Unit cycles automatically when power is on. When servicing, you may be exposed to voltage sources, compressed air, or moving parts. Before servicing unit unplug or disconnect electrical supply to the air compressor, bleed tank of pressure, and allow the air compressor to cool.
To ensure efficient operation and longer life of the air compressor unit, a routine maintenance schedule
should be prepared and followed. The following routine maintenance schedule is geared to an unit in a
normal working environment operating on a daily 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 units in an extremely dirty and/or hostile environment will require a greater
frequency of all maintenance checks.
NOTE: See "Operation" section for the location of controls.
To Check Safety Valve
Risk of Bursting. If 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 operates 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" and unplug unit.
2. Pull the regulator knob out and turn counterclockwise 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.
5. Drain water from air tank by opening drain valve (counter-
clockwise) on bottom of tank.
A00854 16_ ENG
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