Craftsman 919.165612 User Manual

Owner’s Manual
Permanently Lubricated Twin V 2-Stage Stationary
AIR COMPRESSOR
Model No.
919.165612
• Assembly
• Operation
• Maintenance
• 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
A13568 Rev. 0 08/1/05
TABLE OF CONTENTS
WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY GUIDELINES-DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-8
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DUTY CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
SERVICE AND ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-27
REPAIR PROTECTION AGREEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 51
HOW TO ORDER REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
WARRANTY
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 warranty 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
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SPECIFICATION CHART
Model No. 919.165612
Running HP 2.9 Bore 2.375 Stroke-High Pressure .54" Low Pressure 1.45" Voltage-Single Phase 240/60/1 Minimum Branch Circuit Requirement 15 amps Fuse Type Time Delay Air Tank Capacity - Gallons 60 Approximate Cut-in Pressure 145 Approximate Cut-out Pressure 175
SCFM@ 40 psig 9.6 SCFM@ 90 psig 9.0
Refer to Glossary for abbreviations.
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 symbols.
Indicates an imminently hazardous
situation which, if not avoided, will result in death or serious injury.
which, if not avoided, may result in minor
or moderate injury.
Indicates a potentially hazardous situation
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
property damage.
Used without the safety alert symbol
IMPORTANT SAFETY INSTRUCTIONS
Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities contains chemicals known (to the State of California) to cause cancer, birth defects or other 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.
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IMPORTANT SAFETY INSTRUCTIONS
Save these instructions
Improper operation or maintenance of this product could result in serious injury and property damage. Read and understand all warnings and operation instructions before using this equipment.
HAZARD
WARNING: Risk of explosion or fire
What Could Happen
It is normal for electrical contacts within the motor and pressure switch to spark.
If electrical sparks from compressor come into contact with flammable vapors, they may ignite, causing fire or explosion.
Restricting any of the compressor ventilation openings will cause serious overheating and could cause fire.
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.
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HAZARD
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.
What Could Happen
Failure to properly drain condensed water from tank, causing rust and thinning of the steel tank.
Modifications or attempted repairs to the tank.
Unauthorized modifications to the unloader valve, safety valve, or any other components which control tank pressure.
Excessive vibration can weaken the air tank and cause rupture or explosion
ATTACHMENTS & ACCESSORIES:
Exceeding the pressure rating of air tools, spray guns, air operated accessories, tires, and other inflatables can cause them to explode or fly apart,
and could result in serious injury.
HAZARD
How To Prevent It
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.
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 attachments. Never use
compressor to inflate small low pressure objects such as children’s toys, footballs, basketballs, etc.
WARNING: Risk from Flying Objects
What Could Happen
The compressed air stream can cause soft tissue damage to exposed skin and can propel dirt, chips, loose particles,
and small objects at high speed, resulting in property damage or personal injury.
How To Prevent It
Always wear ANSI Z87.1 approved safety glasses with side shields when
using the compressor.
Never point any nozzle or 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.
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HAZARD
WARNING: Risk of Electrical Shock
What Could 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.
HAZARD
WARNING: Risk to Breathing
What Could 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.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides, weed killers, may contain harmful
vapors and poisons.
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.
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.
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 NIOSH/MSHA approved respirator designed for use
with your specific application.
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HAZARD
WARNING: Risk of Burns
What Could Happen
Touching exposed metal such as the compressor head or outlet tubes, can result in serious burns.
HAZARD
WARNING: Risk from Moving Parts
What Could Happen
Moving parts such as the pulley,
flywheel, and belt injury if they come into contact with you or your clothing.
Attempting to operate damaged or missing parts
attempting to repair compressor with protective shrouds removed can expose you to moving parts and
serious injury.
can cause serious
compressor with
or
can result in
HAZARD
How To Prevent It
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
Never operate the compressor with guards or covers which are removed.
Any repairs should be performed by authorized service center personnel.
required on this product
damaged or
WARNING: Risk of Falling
What Could Happen
A portable compressor can fall a table, workbench, or roof c
damage to the compressor and could result in serious injury or death to the operator.
from
ausing
How To Prevent It
Always operate compressor in a stable secure position to prevent accidental
movement of the unit.
compressor on a roof or other elevated position. Use additional air hose to reach high locations.
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Never operate
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HAZARD
WARNING: Risk of Serious Injury or Property Damage
When Transporting Compressor
(Fire, Inhalation, Damage to Vehicle Surfaces)
What Could 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.
HAZARD
WARNING: Risk of Unsafe Operation
How To Prevent It
Always place COMPRESSOR on a protective mat when transporting to
protect against damage to vehicle from leaks. Remove COMPRESSOR from vehicle immediately upon arrival at your destination.
What Could Happen
Unsafe operation of your air compressor could lead to serious injury or death to you or others.
SAVE THESE INSTRUCTIONS
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 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
product.
Equip area of operation with a fire extinguisher.
Do not operate machine with missing, broken, or unauthorized parts.
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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.
ACCESSORIES
The accessories and tools are available through the current Power and Hand Tool Catalog or full-line Sears stores.
Accessories
In Line Filter
Tire Air Chuck
Quick Connector Sets (various sizes)
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.
Air Pressure Regulators
Oil Fog Lubricators
Air Hose: 1/4", 3/8" OR 1/2" I.D. in various lengths
Refer to the selection chart located on the unit to select the tools this unit is capable of powering.
DUTY CYCLE
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.
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ASSEMBLY
Contents of Carton
1 - Air Compressor 1 - Parts bag containing: 1 - Operator’s Manual 1 - Parts Manual 4 - 5/8" Washers
Tools Required for Assembly
1 - 9/16" socket or open end wrench
Electric drill
Unpacking
1. Remove all packaging.
INSTALLATION
Risk of Unsafe
Opertation. It may be necessary to brace or support one side of the unit 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.
HOW TO SET UP YOUR UNIT
Location of the Air Compressor
Locate the air compressor in a clean, dry, and well ventilated area.
Located the air compressor at least 12" away from the wall or other obstructions that will interfere 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 compressor.
Anchoring of the Air Compressor
Risk of Unsafe
Bursting. 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 4 - 3/8" Lag screw to fit
concrete anchors (not supplied)
4 - 5/8" Washer (found in parts
bag) shims (if needed)
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 concrete anchors.
3/8" Lag Screw
5/8" Washer (supplied)
Shim Under Washer (not supplied)
(not supplied)
Surface Line
Concrete Anchor (not supplied)
4. Line-up holes in surface with holes in air compressor feet.
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5. Place the (4) washers (supplied) 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.
Wiring Instructions
RISK OF
ELECTRICAL SHOCK. Improper electrical grounding can result in electrical shock. The wiring should be done by a qualified electrician
A qualified electrician needs to knows the following before wiring:
1. The amperage rating of
the electrical box should be adequate. Refer to the Specification Chart, for this information.
2. The supply line should have the
same electrical characteristics (voltage, cycle, phase) as the motor. Refer to the motor nameplate, 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.
RISK OF ELECTRICAL SHOCK. Electrical wiring must be located away from hot surfaces such as manifold assembly, compressor outlet tubes, heads, or cylinders.
GROUNDING INSTRUCTIONS
This product should be connected to a metallic, permanent wiring system, of an equipment-grounding terminal or lead on the product.
Voltage and Circuit Protection
Refer to the specification chart 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.
Air Distribution System
Risk of Unsafe
Operation. Plastic or PVC pipe is not designed for use with compressed air. Regardless of its indicated pressure rating, plastic pipe can burst from air pressure. Use only metal pipe for air distribution lines.
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.
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DRAIN
TRAP
DRAIN TRAPS
DRAIN
LEGS
MOISTURE
SEPARATOR
AND TRAP
DIRT
LEG
DIRT
LEG
LUBRICATOR
REGULATOR
FILTER
AIR DISCHARGE
VALV
E
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
VALV
E
TYPICAL COMPRESSED
AIR DISTRIBUTION SYSTEM
AIR FLOW
AIR FLOW
FEEDER LINES SLOPE
WITH AIR FLOW
AIR USAGE
LINES
AIR
COMPRESSOR
Use pipe that is the same size as the air tank outlet. Piping that is too small will restrict the flow of air.
If piping is over 100 feet long, use the next larger size.
Bury underground lines below the frost line and avoid pockets where condensation can gather and freeze. Apply pressure before underground lines are covered to make sure all pipe joints are free of leaks.
A flexible coupling is recommended to be installed between the air discharge outlet and main air distribution line to allow for vibration.
A separate regulator is recommended to control the air pressure. Air pressure from the tank is usually to high for individual air driven tools.
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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.
Pressure
Switch
On/Auto/Off
Tank
Pressure Gauge
Switch
Globe Valve
Safety Valve
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" 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).
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Tank Pressure Gauge: The tank pressure gauge indicates the reserve air pressure in the tank.
Globe Valve: Opens and closes air discharge valve. Turn knob counter­clockwise to open and clockwise to close.
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.
Drain Valve
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.
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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.
Check Valve
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.
Pressure
Release
Valve
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".
How to Use Your Unit
How to Stop
1. Set the On/Auto/Off lever to
"OFF".
Before Starting
Break-in Procedure
damage may result if the following break-in instructions are not
closely followed.
This procedure is required 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.
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 globe valve is open and there is minimal air pressure build-up in tank.
6. Check all air line fittings and connections/piping for air leaks by applying a soap solution. Correct if necessary. Minor leaks can cause the air compressor to overwork, resulting in premature breakdown or inadequate performance.
7. Check for excessive vibration.
:
Risk of Unsafe Operation.
NOTE:
Serious
before
the
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Readjust or shim air compressor feet, if necessary.
8. After 15 minutes, close the globe valve. The air receiver will fill to "cut-out" pressure and the motor will stop.
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
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.
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 manufacture instructions.
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