Craftsman 92116477 Owner’s Manual

Owner's Manual

AIR COMPRESSOR

Oil Lubricated Belt Drive, Electric

80 Gallon Vertical TOPS TM -Thermal Overload Protection

System

NOTE: These units DO NOT require a magnetic starter.

Model No. 921.16477

CAUTION:

Before using this product,

read this manual and follow all its Safety Rules and

Operating Instructions.

Sears Brands Management Corporation, Hoffman Estates, IL 60179

www.craftsman.com

4/7/2010 Part No. 200-2796

• Safety Instructions

• Installation & Operation

• Maintenance & Storage

• Troubleshooting Guide

• Parts List

• Espa_ol, p. 18

• Franqais, p. 29

======================

U.S.A.

1_:I:]|: [o]_ [a_o]_/ i :__/ l_'_

WARRANTY ....................................... 2

SERVICE INTERVAL ............................... 11

SPECIFICATION CHART ............................ 2

SAFETY GUIDELINES ............................. 3-4

GLOSSARY OF TERMS ............................. 4

OVERVIEW ....................................... 5

ASSEMBLY ....................................... 5

TYPICAL INSTALLATION ............................ 6

COMPRESSOR CONTROLS ......................... 7

ELECTRICAL POWER REQUIREMENTS ............... 7

OPERATING INSTRUCTIONS ........................ 8

MAINTENANCE ................................. 9-11

TROU BLESHOOTI NG CHART ....................... 12

PARTS DRAWINGS AND PARTS LISTS ............. 13-17

CRAFTSMAN ONE YEAR FULL WARRANTY FOR ONE YEAR from the date of purchase, this product is warranted against any defects in material

or workmanship. Defective product will receive free repair or free replacement if repair is unavailable.

For warranty coverage details to obtain repair or replacement, visit the web site: www.craftsman.com

This warranty does not cover the air filter or drive belt, which are expendable parts that can wear out from normal use within the warranty period.

This warranty is void if this product is ever used while providing commercial services or if rented to

another person.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Sears Brands Management Corporation, Hoffman Estates, IL 60179 U.S.A.

[,,,___o] _I[_

APPROXIMATE

RUNNING TANK CAPACITY VOLTAGE/

MODEL NO. H.P. GALLONS AMPS/PHASE

CUT-IN

PRESSURE

921.16477 145 175

(WV5248069) 5.2 80 (302,8 Liters) 240/22/1 (9,99 bar) (12,1 bar)

APPROXIMATE

CUT-OUT

PRESSURE

2 200-2796

ThefollowinginformationrelatestoprotectingYOURSAFETYandPREVENTINGEQUIPMENTPROBLEMS.Tohelpyourecognize thisinformation,weusethefollowingsymbols.Pleasereadthemanualandpayattentiontothesesections.

__ - A POTENTIAL HAZARD THAT WILL CAUSE SERIOUS INJURY OR LOSS OF LIFE. _k_- A POTENTIAL HAZARD THAT COULD CAUSE SERIOUS INJURY OR LOSS OF LIFE. __ - A POTENTIAL HAZARD THAT MAY CAUSE MODERATE INJURY OR DAMAGE TO

EQUIPMENT.

RISK OF FIRE OR EXPLOSION.

RISK OF BURSTING.

RISK OF ELECTRICAL SHOCK.

RISK OF INJURY.

RISK OF BURSTING.

RISK OF BURNS.

RISK TO BREATHING/INHALATION HAZARD..

RISK TO BREATHING.

RISK OF EYE INJURY.

RISK OF BURSTING.

Never spray flammable liquids in a confined area. It is normal for the motor and pressure switch to produce sparks while operating. If sparks come into contact with vapors from gasoline or other

solvents, they may ignite, causing fire or explosion. Always operate the compressor in a well-ventilated area. Do not smoke while spraying. Do not spray where sparks or flame are

)resent. Keep compressor as far from spray area as possible. Store flammable materials in a

secure location away from compressor. Equip the area of operation with a fire extinguisher. Do not weld, drill or modify the air tank of this compressor. Welding or modifications on the air

compressor tank can severely impair tank strength and cause an extremely hazardous condition. Welding or modifying the tank in any manner wilt void the warranty. If tank develops a leak, replace

it immediately with a new tank or replace the entire compressor. Never use an electric air compressor outdoors when it is raining or on a wet surface, as it may

cause an electric shock. Failure to provide adequate grounding to this product could result in serious injury or death from electrocution. Make certain that the electrical circuit to which the

compressor is connected provides proper electrical grounding, correct voltage and adequate fuse

)rotection.

This unit starts automatically. ALWAYS shut off the main power disconnect, and bleed all pressure from the system before servicing the compressor, and when the compressor is not in use. Do not use the unit with the shrouds or belt guard removed. Serious injury could occur from contact with moving parts. Stay alert and watch what you are doing when operating the compressor. Do not use the compressor while tired or under the influence of drugs or alcohol.

Check the manufacturer's maximum pressure rating for air tools and accessories. Compressor outlet pressure must be regulated so as to never exceed the maximum pressure rating of the tool. Relieve all pressure through the hose before attaching or removing accessories. Never use compressor to inflate small low pressure objects such as children's toys, footballs, basketballs, etc.

High temperatures are generated by the pump and manifold. To prevent burns or other injuries, DO NOT touch the pump, manifold or transfer tube while the pump is running. Allow them to cool before handling or servicing. Keep children away from the compressor at all times. Do not reach around protective shrouds or attempt to maintenance until unit has been allowed to cool.

Always wear MSHA/NIOSH approved, properly fitting face mask or respirator and work in a well ventilated area when using tools that generate dust. Some dust created by power

sanding, grinding, drilling and other construction activities contains chemicals known (to the State of California) to cause cancer, birth defects or other reproductive harm. Some examples 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.

Be certain to read all labels when you are spraying paints or toxic materials, and follow the safety instructions provided on the label or safety sheets for the materials you are spraying. Use a MSHA/NIOSH approved respirator mask if there is a chance of inhaling anything you are spraying. Read all instructions and be sure that your respirator mask will protect you. Work in an area with good cross ventilation.

Always wear ANSI Z87.1 approved safety goggles when using an air compressor. Never point any nozzle or sprayer toward a person, animal or any part of the body. Equipment can cause serious injury if the spray penetrates the skin.

•Do not adjust the tank safety valve for any reason. Doing so voids all warranties. The relief valve has been pre-set at the factory for the maximum pressure of this unit. Personal injury and/or property damage may result if the relief valve is tampered with.

•Do not use plastic or pvc pipe for compressed air. Use only galvanized steel pipe and fittings for compressed air distribution lines.

200-2796 3

RISK OF FIRE.

RISK TO BREATHING.

RISK OF INJURY

RISK TO HEARING. Always wear hearing protection when using an air compressor. Failure to do so may result in

NOTE: ELECTRICAL WIRING. Refer to the air compressor's serial label for the unit's voltage and amperage requirements. Ensure

Unattended operation of this compressor could result in personal injury or property damage. To reduce the risk of fire, do not allow the compressor to operate unattended. Always disconnect electrical power by turning the pressure switch to off and drain the tank daily or after each use.

Air obtained directly from the compressor should never be used to supply air for human consumption. The air stream may contain carbon monoxide, toxic vapors, or solid particles from tank. Breathing these contaminant's can cause serious injury or death. 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 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.

Always operate the compressor in a stable secure position to prevent accidental movement of the unit. Never operate the compressor on a table, workbench, roof or other elevated position. Use additional air hose to reach high locations.

hearing loss.

The interconnect cord on this product contains lead, a chemical known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling.

that all wiring is done by a licensed electrician, in accordance with the National Electrical code.

ANI!NNI!

Drain the moisture from the tank on a daily basis. A clean, dry tank will help prevent corrosion. Pull the tank safety valve ring daily to ensure that the valve is functioning properly, and to clear the valve of any possible obstructions.

To provide proper ventilation for cooling, the compressor must be kept a minimum of 12 inches (31 cm) from the nearest walt, in a welt-ventilated area. Restricting any of the compressor ventilation openings will cause overheating and could cause fire, never place objects against or on top of compressor.

Fasten the compressor down securely if transporting is necessary. Pressure must be released from the tank before transporting. Protect the air hose and interconnect cord from damage and puncture. Inspect them weekly for weak or worn spots, and replace if

necessary. To reduce the risk of electric shock, do not expose to rain. Store indoors.

On oit-lubed compressors, oil can leak or spill and could result in fire or breathing hazard. Oil leaks wilt damage paint, carpet or other surfaces in vehicles or trailers. Always place the compressor on a protective mat when transporting to protect against damage to vehicle from leaks. Remove compressor from vehicle immediately upon approval at your destination.

To prevent damage to tank and compressor on stationary models, the tank must be shimmed so the pump base is level within 1/8" to

distribute oil properly. All feet must be supported, shimming where necessary, prior to attaching to the floor. Fasten all feet to floor. We also recommend the use of vibration pads (094-0137) under tank feet.

CFM: Cubic feet per minute; a unit of measure of air flow. PSI: Pounds per square inch; a unit of measure of air pressure. 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 factory set tow pressure point, the motor wilt 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 the factory set high pressure point 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. Well-ventilated: Means of providing fresh air in exchange for

dangerous exhaust or vapors. Dedicated circuit: An electrical circuit reserved for the exclusive

use of the air compressor.

4 200-2796

BASIC AIR COMPRESSOR COMPONENTS

The basic components of the air compressor are the electric

motor, pump, pressure switch and tank (see Fig. 1).

The electric motor (see A) powers the pump. TOPS senses both temperature and current, providing more

complete motor overload protection than a magnetic starter,

which senses only current. If TOPS senses an overload condition,

it wilt automatically shutdown the compressor. Allow 10-15 minutes for the unit to cool down, then press the reset button on the motor to restart the compressor.

The pump (see B) compresses the air and discharges it into

the tank.

The tank (see C) stores the compressed air.

The pressure switch (see D) shuts down the motor when the tank reaches a pre-set "cut-out" pressure. As compressed air is used and the tank drops to a pre-set "cut-in" pressure, the switch restarts the motor automatically, and the pump resumes compressing air.

Fig. 1

ASSEMBLING THE COMPRESSOR

This compressor was shipped with oil in the pump

crankcase. Check oil before operating the air compressor,

see Check Oil under Maintenance.

Unpack the air compressor. Inspect the unit for damage. If

the unit has been damaged in transit, contact the carrier

and complete a damage claim. Do this immediately

because there are time limitations to damage claims.

The carton should contain:

• air compressor

• operator/parts manual

2. Check the compressor's serial label to ensure that you

have received the model ordered, and that it has the

required pressure rating for its intended use.

3. Locate the compressor according to the following

guidelines:

a. For optimum performance, locate the compressor close

to the power panel, as specified in ELECTRICAL POWER REQUIREMENTS, and as close as possible to the place where the air wilt be used. This ensures

maximum power to the compressor and maximum air pressure to the tool. If both of these conditions

cannot be met, it is better to locate the compressor close to the power panel, and use a longer air hose to reach the usage area.

b. The flywheel side of the compressor must be at least

12 inches (31 cm) from any wall or obstruction, in a clean, well-ventilated area, to ensure sufficient air

flow and cooling.

c. In cold climates, locate the compressors in a

heated building when not in use. This wilt reduce problems with lubrication, motor starting and freezing

of water condensation.

Remove the compressor from the shipping pallet and place it on the floor or a hard, level surface. The

compressor must be level to ensure proper lubrication of the pump and good drainage of the moisture in the tank.

__The shipping pallet is not designed as a

base for an operating compressor. Operating the compressor while it is on the pallet will void your

warranty.

To prevent damage to tank and pump, the tank must be shimmed so the pump is level within 1/8" per lineal foot

maximum to distribute oil properly. Fasten to floor and NEVER force tank feet to floor without shims when

tightening. We also recommend the use of vibration pads (094-0137) under tank feet (E).

4. Connect an air hose (not included) to the compressor.

Fig. 2

200-2796 5

__[[[_Risk ofbursting,resultingininjury.

Neveruseplasticpipeforcompressedair.

_lhl__Never uselubricatorforpaintspraying

orsimilarapplications.

A Airflow B Feederline

C Drainleg D Moisturetrapwithdrain E Non-lubricatedsupplyline

F 1/4turnvalve

G Bypass

H Airdryeroraftercooler

J Linefilter

K Dripteewithdrain

L Air/waterfilterwithpetcock

M Regulator

N Lubricator P Quickcoupler

R Airhosetotool T Flexibleairline

Air dryers and after coolers

An air dryer or aftercooler is installed directly in the air line.

Moisture removal and air filtration

As the air cools, moisture will condense in the lines. This

moisture must be removed before it reaches the tool being used. To remove this moisture, run the main air line downhill to a

moisture trap and drain. Air/water filters should also be installed in the positions shown.

Air pressure regulation

The air pressure gauge on the pressure switch measures air pressure inside the tank, not pressure in the airline. Install an air regulator in the drop line for each tool, to regulate air pressure to

that tool. Never exceed the maximum pressure rating of the tool.

Air lubrication

Install an air lubricator only for those tools requiring lubrication. Do not use a lubricator for paint spraying or similar applications. The oil will contaminate the paint and ruin the job.

Shut-off valves

Install shut-off valves in each drop line, to isolate the tool and its accessories for servicing. You can also install a bypass line around an accessory.

6 200-2796

Main Power Disconnect

Install a main power disconnect switch in the power line to the compressor, near the compressor's location. It is operated manually, but when it is in the ON position, the compressor will start up or shut down automatically based on air demand.

ALWAYS operate this switch to OFF when the compressor is not

being used. Pressure switch (see A)

This switch turns on the compressor. It is operated manually, but when in the ON position, it allows the compressor to start up or shut down automatically, without warning, upon air demand.

ALWAYS set this switch to OFF when the compressor is not

being used, and before unplugging the compressor.

__For your safety, tank pressure is preset

within the switch and must never be tampered with.

This switch must not be adjusted by the operator; doing so

will void the warranty. The pressure switch controls the level of air

pressure in the tank by automatically starting and stopping the motor, as required to maintain the factory preset pressure level.

The pressure switch also automatically bleeds pressure from the pump head when the pump stops. This feature eliminates back pressure in the pump, ensuring easier starting.

Tank Safety Valve (see B)

Used to allow tank pressure to escape into the atmosphere.

If the pressure switch does not shut off the compressor at it's "cut-out" pressure setting, the safety valve wilt protect against high pressure by releasing tank pressure at it's factory set pressure (slightly higher than the pressure switch "cut-out" setting). To operate manually, pull the ring on the valve to relieve air pressure in the tank.

Pressure Release Valve (see C)

The pressure release valve (located on the bottom of the pressure switch), is designed to release compressed air from the compressor head and outlet tube when the compressor reaches "cut-out" or is shut off. The pressure 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 after brief release after reaching "cut-out" pressure.

Tank Pressure Gauge (see D)

This gauge measures the pressure level of the

air stored in the tank. It is not adjustable by the

operator, and does not

indicate line pressure.

MOTOR RESET SWITCH

__Ensure that all guards and shrouds are in

place before pressing the reset switch to restart the motor.

TOPS senses both temperature and current, providing more

complete motor overload protection _Fig. 4 senses only current. If TOPS

senses an overload condition, it will E

than a magnetic starter, which __' ' _, automatically shut down the compressor. Allow 10-15 minutes

for the unit to cool down, than press

the reset button on the motor to restart the compressor.

If the motor shuts down because of overload, wait 10-15 minutes so the motor can cool down, then press (NEVER force) the reset switch (see E) to restart the motor (see Fig. 4).

ELECTRICAL WIRING

Refer to the air compressor's serial label for the unit's voltage and amperage requirements. Ensure that all wiring is done by a licensed electrician, in accordance with the National Electrical Code. Use electrical conduit to protect the wiring.

MAIN POWER PANEL

For best performance and reliable starting, the air compressor must be installed on a dedicated circuit, as close as possible to the electrical power panel. Provide circuit

breaker or fuse protection at your main power panel. Use time delay fuses on the circuit, because the compressor will momentarily draw several times its specified amperage when first

started. 200-2796 7

MAIN POWER DISCONNECT SWITCH

Install a main power disconnect switch in the line from the panel to the compressor. The main power disconnect switch must be located near the compressor, for ease of use and safety. When turned OFF, the main power disconnect switch shuts off all power to the compressor. When it is turned ON, the compressor wilt start and stop automatically, controlled by the pressure

switch.

LOW VOLTAGE PROBLEMS

Low voltage wilt cause difficult starting or an overload. Low voltage can be caused by a low supply voltage from the local power company, other equipment running on the same line, or

inadequate wiring. If any other electrical devices are drawing from

the compressor's circuit, it may fail to start.

Low voltage to the compressor can be caused by a supply wire of insufficient gauge for the distance between the compressor and the power source. The longer the distance, the larger the wire gauge (lower the number) must be, to overcome the inherent voltage loss caused by the wire resistance. Refer to the National Electrical Code to determine proper wire size for your circuit.

If the wiring is not adequate, the input voltage will drop by 20 to 40 volts at startup. Low voltage or an overloaded circuit can result in sluggish starting that causes the circuit breaker to trip, especially in cold conditions.

GROUNDING INSTRUCTIONS

This product must be connected to a grounded, metallic, permanent wiring system, or an equipment - grounding terminal or lead on the product.

BREAK-IN OF THE PUMP NOTE: The pump is shipped with breakiin oil which should be

changed after the first 8 hours of operation.

1. Make sure the power is connected at the power panel.

2. Check the oil level in the pump (see "Checking the Oil" in the maintenance section).

3. Open the petcock (see C).

_[__ Escaping air and moisture can

propel debris that may cause eye injury. Wear safety goggles when opening petcock.

Turn ON the main power disconnect switch. Turn the pressure switch to the AUTO position (see B). The motor should start. Allow the compressor to run for 30 minutes, to break in the internal parts.

before starting. If the compressor will not start, relocate it in a warmer location.

SHUTDOWN

1. Turn the pressure switch to the OFF position (see A).

2. Shut OFF the main power disconnect switch.

3. Reduce pressure in the tank through the outlet hose. You can also pull the tank safety valve ring (see E) and keep it open to relieve pressure in the tank

_[__ Escaping air and moisture can

propel debris that may cause eye injury. Wear safety goggles when opening petcock.

Open the petcock (see C) to allow moisture to drain from the tank.

NOTE:

After about 30 minutes, if the unit does not operate

properly, SHUT DOWN IMMEDIATELY, and contact a Sears or other qualified service center. DO NOT return the unit to the store where it was purchased.

5. After about 30 minutes, turn the pressure switch to the OFF position (see A).

6. Shut OFF the main power disconnect.

7. Close the petcock (see D). Turn in the clockwise direction.

8. Turn the pressure switch to the AUTO position. The compressor wilt start and fill the tank to the cut-out pressure and stop.

NOTE: As compressed air is used, the pressure switch will

restart the motor automatically to supply more compressed air to the tank.

DAILY START-UP

Check the oil level in the pump (see "Checking the Oil" in the maintenance section).

Make sure the main power disconnect switch is shut OFF.

Close the tank petcock (see D).

Turn ON the main power disconnect switch. Turn the pressure switch to the AUTO position (see B). The pump will start filling the tank with air. When the air pressure in the tank reaches the level preset at the factory, the pressure

switch wilt turn off the electric motor. As air is used and the pressure level in the tank drops, the pressure switch will start

the motor and the pump will begin refilling the tank.

(B) AUTO

/" E

," ',

',, _ JW ;

OFF (A)

__ High temperatures are generated

by the pump. To prevent burns or other injuries, DO NOT touch the pump or transfer tube while the pump is running. Allow it to cool before handling or servicing. Keep children away from the compressor

at all times.

NOTE: If the unit does not operate properly, SHUT DOWN

IMMEDIATELY, and contact a Sears or other qualified service center.

COLD WEATHER STARTING

In cold weather check that the air filters are clean.

NOTE: Use synthetic, non-detergent air compressor oil.

Open the petcock (C) to depressurize the tank to zero PSI

8 200-2796

MAINTENANCE

__ To avoid personal injury, always shut off

and unplug the compressor and relieve all air pressure from the system before performing any service on the air

compressor.

Regular maintenance will ensure trouble-free operation. Your electric powered air compressor represents high-quality engineering and construction; however, even high-quality machinery requires periodic maintenance. The items listed below should be inspected on a regular basis

DRAINING THE TANK

Drain the moisture from the tank (for instructions, see "Shutdown" in the operating instructions section).

__Condensation will accumulate in

the tank. To prevent corrosion of the tank from the inside, this moisture must be drained at the end of every workday. Wear protective eyewear.

CHECKING THE OIL

Check the level of oil in the pump with the sight glass. The pump oil level must be between A and B. Do not overfill or

underfitt.

NOTE: Use synthetic, non-detergent air compressor oil.

CHANGING THE OIL

guard removed. Serious injury could occur from contact with moving parts.

Proper belt tension and pulley alignment must be maintained for maximum drive efficiency and belt life. The correct tension exists if a deflection (see A) of 112" (13 mm) occurs by placing 10 lbs. (4.6 kg) of force (see B) midway between the motor pulley and the pump flywheel (See Fig. 8). This deflection can be adjusted by the following procedure. The pulley should be carefully aligned with the flywheel, and all setscrews should be

kept tight.

1. Remove the front of the beltguard by turning the 4 belt guard clips 1/4 turn counter-clockwise using a 518"wrench.

2. Loosen the motor mounting bolts.

3. Shift the motor to the point where the correct deflection exists (A & B).

4. Retighten the motor mounting bolts to 130-180 in.-lbs.

5. Check to ensure that the tension remained correct.

6. Reinstall the belt guard. All moving parts must be guarded.

Fig. 8

Motor

Remove the oil plug (C) and drain the oil until it slows to a drip, then close. Unscrew the oil fill plug (D) and add compressor oil (approx 21 oz.) until it is between full (A) and add (B). Replace the oil fill plug. Never overfill or under fill the pump.

NOTE: The compressor is pre-fitted with synthetic oil. Use synthetic, non-detergent air compressor oil.

A = Full B =Add

C = Oil Plug D = Oil Fill Plug

Fig. 7

DRIVE BELT TENSION ADJUSTMENT

NOTE: Drive belt tensioning and pulley alignment are done at the same time. They are discussed separately for clarity.

__ This unit starts automatically.

ALWAYS shut off the main power disconnect, and bleed all pressure from the system before servicing the compressor, and when the compressor is not in

use. Do not use the unit with the shrouds or belt

Pump Fl_heel

Compressor

Motor

may vary from

one shown

Motor

moL

bo#s

PULLEY ALIGNMENT

NOTE: Drive belt tensioning and pulley alignment are done at

the same time. They are discussed separately for clarity.

__This unit starts automatically.

ALWAYS shut off the main power disconnect, and

bleed all pressure from the system before servicing

the compressor, and when the compressor is not in

use. Do not use the unit with the shrouds or belt

guard removed. Serious injury could occur from contact with moving parts.

200-2796 9

NOTE:Oncethemotorpulleyhasbeenmovedfromitsfactory

setlocation,thegroovesoftheflywheelandpulleymust bealignedtowithin1/16"topreventexcessivebeltwear.

Tocheckpulleyalignment,removethebeltguardandplace astraightedge(seeA)againstthepumpflywheel(seeB)(See

Fig. 9). Measure and record the distance from the straightedge to the edge of the drive belt at point C. Then measure the distance

from the straightedge to the edge of the drive belt again at points

D and E. Both distances should be the same as at point C. If D or E are different from C, there is a misalignment which must be corrected before the compressor is run. To correct a pulley misalignment, use the following procedure.

1. Remove the front of the beltguard by turning the 4 belt guard

clips 1/4 turn using a 5/8" wrench.

2. Loosen the motor mounting bolts.

3. Loosen the setscrew on the motor pulley.

4. Align the motor pulley with the pump flywheel (C-D-E must

be equal ).

5. Retighten the motor pulley setscrew to 85-90 in.-Ibs.

6. Adjust the proper belt tension.

7. Retighten the motor mounting bolts to 130-180 in.-Ibs.

8. Reinstall the belt guard. All moving parts must be

guarded.

Fig. 9

MOtOr / pulley

Compressor

may vary from

one shown

DRIVE BELT REPLACEMENT

__This unit starts automatically.

ALWAYS shut off the main power disconnect, and bleed all pressure from the system before servicing the compressor, and when the compressor is not in

use. Do not use the unit with the shrouds or belt guard removed. Serious injury could occur from

contact with moving parts.

1. Remove the front of the beltguard by turning the 4 belt guard

clips 1/4 turn using a 5/8" wrench.

2. Loosen the motor mounting bolts.

3. Shift the motor towards the pump to the point where the belt

can be easily removed and installed.

4. Remove and replace belt. NOTE: The belt must be centered over the grooves on the flywheel and motor pulley.

5. Shift the motor back to the point where the correct deflection exists (see "Drive Belt Tension Adjustment").

6. Retighten the motor mounting bolts to 130-180 in.-lbs.

7. Check to ensure that the tension remained correct.

8. Reinstall the belt guard. All moving parts must be guarded.

TO REPLACE OR CLEAN CHECK VALVE

__This unit starts automatically.

ALWAYS shut off the main power disconnect, and

bleed all pressure from the system before servicing

the compressor, and when the compressor is not in

use. Do not use the unit with the shrouds or belt

guard removed. Serious injury could occur from contact with moving parts.

1. Turn air compressor off, remove the power cord from jiA

the outlet or lock out the To pump power supply and relieve all head _"@'c

the air pressure from the tank cC:z--, j\, / D (refer to "Shutdown" in

Operating Instructions).

Make sure the compressor

has cooled down before servicing.

2. Using the appropriately LJ jI"A E sized wrench, loosen the _J_ /_ F

compression nuts (A) on the _:%__J_.

check valve (B) and pump .......

head (C). Remove the "_ transfer tube (D). C..

3. Using the appropriately _nk sized wrench, loosen the compression nut (F) from the elbow (G), located on the side of the check valve. Remove the bleeder tube (E) and gently push aside.

4. Making note of the orientation for reassembly, unscrew the check valve from the tank (counterclockwise) using a 1-3/16" open end wrench.

5. Using a pencil or screwdriver, carefully Set,driver push the valve disc up and down. If the penc4_

valve disc does not move freely up and down, the check valve needs to be cleaned or replaced.

6. Clean the check valve with warm soapy water and make sure to dry thoroughly before reinstalling. If the disc valve still does not move freely up and down, it will need to be replaced.

7. Apply thread sealant to the check valve threads and reinstall into the tank by turning clockwise. Make sure it is the same orientation as when it was CheckValve

removed.

8. Replace the bleeder tube and tighten compression nut.

9. Replace the transfer tube and tighten compression nuts.

10. Perform the "Break-in of the pump" procedure in the Operating Instructions to make sure there are no leaks and the check valve is working properly.

4:.

10 200-2796

CLEANINGTHEAIR FILTER

A dirty air filter will

reduce the A = Wing nut compressor's 8 C C = Filter element

performance and life. To avoid any internal

contamination of the pump, the filter should

be cleaned frequently, and replaced on a regular basis. Felt filters

should be cleaned in

warm, soapy water,

rinsed, and allowed to air dry before

reinstaltation. Paper filters should be replaced when dirty. Do not allow the filter to become filled with dirt or paint. If the filter becomes filled with paint, it should be replaced. Direct exposure to dirty conditions or painting areas will void your warranty.

CHECKING THE RELIEF VALVE

Pull the tank safety valve daily to ensure that it is operating

properly and to clear the valve of any possible obstructions.

TESTING FOR LEAKS

Check that all connections are tight. A small leak in any of the hoses, transfer tubes, or pipe connections wilt substantially reduce the performance of your air compressor. If you suspect a leak, spray a small amount of soapy water around the area of the suspected leak with a spray bottle. If bubbles appear, repair or replace the faulty component. Do not over tighten any

connections.

B = Metal cover

STORAGE

Before storing the compressor for a prolonged period, use an

air blow gun to clean all dust and debris from the compressor.

Disconnect the power cord and coil it up. Pull the tank safety valve to release all pressure from the tank. Drain all moisture from the tank. Clean the filter element and filter housing; replace the element if necessary. Drain the oil from the pump crankcase and replace it with new oil. Cover the entire unit to protect it from

moisture and dust.

Daily or Every 200 Every 250 After first 8 hours

after operating operating and then every 500

Perform the following maintenance at the intervals indicated below, each use hours hours operating hours

Inspect air filter (clean or replace as necessary) •

Check pump oil level •

Change pump oil (Use synthetic, non-detergent air compressor oil) •

Operate the tank safety valve • Check belt tension •

Drain tank •

Check and tighten all bolts (do not over tighten) •

200-2796 11

Note: Troubleshooting problems may have similar causes and solutions.

PROBLEM POSSIBLE CAUSE SOLUTION Excessive current draw Low voltage/motor overload Check that power supply is adequate and that compressor is on a

trips circuit breaker or dedicated circuit. motor reset switch Drive belt tension too tight Readjust belt tension.

Restricted air passages Inspect and replace transfer tubes or the check valve, (see "To replace

or clean check valve" in the maintenance section).

Compressor stalls Low voltage to motor Furnish adequate power.

Bad check valve Replace the check valve (see "To replace or clean check valve" in the

maintenance section).

Seized pump Contact a Sears or other qualified service center.

Low discharge pressure Air leaks Tighten or replace leaking fittings or connections. Do not overtighten.

Leaking valves Contact a Sears or other qualified service center. Restricted air intake Clean or replace air filter element(s). Blown gaskets Contact a Sears or other qualified service center.

Worn piston rings or cylinder Contact a Sears or other qualified service center.

Compressor pump Loose motor pulley or pump Retighten pulley and flywheel. Check alignment. knocking flywheel

Low oil level in pump crankcase Keep oil at proper level at all times. Excess carbon on valves or top of Contact a Sears or other qualified service center.

3iston

Oil in discharge air Worn piston rings or cylinder Contact a Sears or other qualified service center.

Restricted air intake Clean or replace the air filter element(s). Oil level too high Reduce to proper level.

Overheating Poor ventilation Relocate compressor to an area with cool, dry, well circulated air, at

Dirty cooling surfaces Clean all cooling surfaces thoroughly. Restricted air passages Inspect and replace transfer tubes or the check valve, (see "To replace

Excessive belt wear Pulley out of alignment Realign pulley with compressor flywheel.

Improper belt tension Readjust.

Pulley wobbles Replace the pulley and check for a damaged crankshaft or flywheel. Compressor won't start Too much back pressure in tank Open petcock when starting motor. in cold temperatures 40W oil in crankcase Use synthetic, non-detergent air compressor oil.

Compressor too cold Move compressor to a warmer location. Air leaking through Dirty or defective check valve. Replace or clean the check valve (see "To replace or clean check

bleeder valve after valve" in the maintenance section). compressor shuts off

least 12 in. from nearest wall.

or clean check valve" in the maintenance section).

12 200-2796

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