OWNERS MANUAL FOR
Permanently Lubricated Twin Cylinder Air Compressor
Specification Chart
Model No.
Horsepower
Bore
Stroke
Voltage/Hertz/Phase
Minimum Branch Circuit Requirement
Fuse Type
Air Tank Capacity - GAL
Approximate Cut-in Pressure
Approximate Cut-out Pressure
SCFM @ 40 psig
SCFM @ 90 psig
FTV560V
5
2 3/8"
1.2"
220V/50/1
15 amps
"Fusetron" Type T
60 Gal. ASME
100
125
14.0
10.5
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 to the right. Please read the
manual and pay attention to these
sections.
Retain Original Sales Receipt as Proof of
Purchase for Warranty Repair Work.
MGP-FTV560VA 9/14/99
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death of serious injury.
CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a poten-
tially hazardous situation which, if not avoided, may result in
property damage.
10/2/97
TABLE OF CONTENTS
SAFETY GUIDELINESSAFETY GUIDELINES
SAFETY GUIDELINES
SAFETY GUIDELINESSAFETY GUIDELINES
WARNING CHARTWARNING CHART
WARNING CHART
WARNING CHARTWARNING CHART
GLOSSARYGLOSSARY
GLOSSARY
GLOSSARYGLOSSARY
DUTY CYCLEDUTY CYCLE
DUTY CYCLE
DUTY CYCLEDUTY CYCLE
GENERAL INFORMATIONGENERAL INFORMATION
GENERAL INFORMATION
GENERAL INFORMATIONGENERAL INFORMATION
ON-RECEIPT INSPECTIONON-RECEIPT INSPECTION
ON-RECEIPT INSPECTION
ON-RECEIPT INSPECTIONON-RECEIPT INSPECTION
DESCRIPTION OF OPERATIONDESCRIPTION OF OPERATION
DESCRIPTION OF OPERATION
DESCRIPTION OF OPERATIONDESCRIPTION OF OPERATION
INSTALLATION AND BREAK-ININSTALLATION AND BREAK-IN
INSTALLATION AND BREAK-IN
INSTALLATION AND BREAK-ININSTALLATION AND BREAK-IN
PROCEDURESPROCEDURES
PROCEDURES
PROCEDURESPROCEDURES
Removal of Shipping Boards and Installation ...................... 6
Location of Air Compressor.................................................... 7
Lubrication and Oil .................................................................. 7
Extension Cords ...................................................................... 7
Voltage and Current Protection .............................................. 7
Piping........................................................................................ 7
Grounding Instructions ........................................................... 7
Additional Regulators & Controls .......................................... 7
Break-in Procedures................................................................ 7-8
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OPERATING PROCEDURESOPERATING PROCEDURES
OPERATING PROCEDURES
OPERATING PROCEDURESOPERATING PROCEDURES
Daily Start-up Checklist .......................................................... 8
MAINTENANCEMAINTENANCE
MAINTENANCE
MAINTENANCEMAINTENANCE
Air Filter - Inspection and Replacement .............................. 9
Safety Valve - Inspection ...................................................... 9
Motor....................................................................................... 9
Check Valve Replacement .................................................... 9
STORAGESTORAGE
STORAGE
STORAGESTORAGE
TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE
PARTS LISTING.....................................................................12-13
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........................................................................... 9
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................................................................. 8-9
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................................................. 8
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........................................ 10-11
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2 ENG
IMPORTANT SAFETY INSTRUCTIONS
• SAVE THESE INSTRUCTIONS •
IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY
AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT.
HAZARD
RISK OF BURSTING
WHAT CAN HAPPEN
AIR TANK
THE FOLLOWING CONDITIONS COULD
LEAD TO A WEAKENING OF THE TANK, AND
RESULT IN A VIOLENT TANK EXPLOSION:
FAILURE TO PROPERLY DRAIN
1.
CONDENSED
CAUSING RUST AND THINNING OF THE
STEEL TANK.
2. MODIFICATIONS OR ATTEMPTED
REPAIRS TO THE TANK.
3. UNAUTHORIZED MODIFICATIONS TO
THE PRESSURE SWITCH, SAFETY
VALVE, OR ANY OTHER COMPONENTS
WHICH CONTROL TANK PRESSURE.
WATER FROM THE TANK,
ATTACHMENTS & ACCESSORIES
EXCEEDING THE PRESSURE RATING OF
AIR TOOLS, SPRAY GUNS, AIR OPERATED
ACCESSORIES, TIRES AND OTHER
INFLATABLES CAN CAUSE THEM TO EX-
PLODE OR FLY APART, AND COULD RESULT
IN SERIOUS INJURY.
HOW TO PREVENT IT
DRAIN TANK DAILY OR AFTER EACH USE.
IF TANK DEVELOPS A LEAK, REPLACE IT
IMMEDIATELY WITH A NEW TANK OR NEW
COMPRESSOR OUTFIT.
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 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.
RISK OF
EXPLOSION OR FIRE
EXCESSIVE VIBRATION CAN WEAKEN THE
AIR TANK OF A STATIONARY COMPRESSOR
AND CAUSE AN EXPLOSION.
IT IS NORMAL FOR ELECTRICAL
CONTACTS WITHIN THE MOTOR AND
PRESSURE SWITCH TO SPARK.
IF ELECTRICAL SPARKS FROM COMPRES-
SOR 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.
3 ENG
THE COMPRESSOR MUST BE PROPERLY
MOUNTED, SEE INSTALLATION PROCE-
DURES.
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.
CONTINUE NEXT PAGE
*
HAZARD
WHAT CAN HAPPEN
HOW TO PREVENT IT
RISK OF
ELECTRICAL SHOCK
RISK FROM
FLYING OBJECTS
YOUR AIR COMPRESSOR IS POWERED BY
ELECTRICITY. LIKE ANY OTHER ELECTRI-
CALLY POWERED DEVICE,
PROPERLY IT MAY CAUSE ELECTRIC SHOCK.
REPAIRS ATTEMPTED BY UNQUALIFIED
PERSONNEL CAN RESULT IN SERIOUS
INJURY OR DEATH BY ELECTROCUTION.
ELECTRICAL GROUNDING:
PROVIDE ADEQUATE GROUNDING TO THIS
PRODUCT COULD RESULT IN SERIOUS
INJURY OR DEATH FROM ELECTROCUTION.
SEE GROUNDING INSTRUCTIONS.
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.
IF IT IS NOT USED
FAILURE TO
NEVER OPERATE THE COMPRESSOR OUTDOORS WHEN IT IS RAINING OR IN WET
CONDITIONS.
NEVER OPERATE COMPRESSOR WITH
COVER COMPONENTS REMOVED OR DAM-
AGE.
ELECTRICAL WIRING OR REPAIRS
ANY
REQUIRED ON THIS PRODUCT
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.
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 OFF THE COMPRESSOR,
BLEED PRESSURE FROM THE AIR HOSE AND
TANK, AND DISCONNECT FROM POWER
SOURCE BEFORE PERFORMING MAINTE-
NANCE OR ATTACHING TOOLS AND ACCESSORIES.
SHOULD BE
RISK TO BREATHING
RISK FROM
MOVING PARTS
RISK OF BURNS
THE COMPRESSED AIR FROM YOUR COMPRESSOR IS NOT SAFE FOR BREATHING!
THE AIR STREAM MAY CONTAIN CARBON
MONOXIDE, TOXIC VAPORS OR SOLID PARTICLES.
SPRAYED MATERIALS SUCH AS PAINT, PAINT
SOLVENTS, PAINT REMOVER, INSECTICIDES,
WEED KILLERS, ETC.. CONTAIN HARMFUL
VAPORS AND POISONS.
THE COMPRESSOR CYCLES AUTOMATI-
CALLY WHEN THE PRESSURE SWITCH IS IN
THE ON/AUTO POSITION.
MOVING PARTS CAN CAUSE SERIOUS
INJURY OR DAMAGE IF THEY COME INTO
CONTACT WITH YOU OR YOUR CLOTHING.
ATTEMPTING TO OPERATE OR REPAIR
COMPRESSOR WITH PROTECTIVE SHROUDS
REMOVED CAN EXPOSE YOU TO MOVING
PARTS AND ELECTRICAL SHOCK.
TOUCHING EXPOSED METAL SUCH AS THE
COMPRESSOR HEAD OR OUTLET TUBE CAN
RESULT IN SERIOUS BURNS.
NEVER INHALE AIR FROM THE COMPRESSOR EITHER DIRECTLY OR FROM A BREATH-
ING DEVICE CONNECTED TO THE COMPRESSOR.
WORK IN AN AREA WITH GOOD CROSSVENTILATION. 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 DE-
SIGNED FOR USE WITH YOUR SPECIFIC
APPLICATION.
ALWAYS TURN OFF THE COMPRESSOR,
BLEED PRESSURE FROM THE AIR HOSE AND
TANK, AND DISCONNECT FROM POWER
SOURCE BEFORE PERFORMING MAINTE-
NANCE OR ATTACHING TOOLS AND ACCESSORIES.
DO NOT REMOVE THE PROTECTIVE COVERS
FROM THIS PRODUCT. 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.
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.
SCWORPOL 7/23/97
4 ENG
GLOSSARY
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.
ASME: American Society of Mechanical Engineers; made,
tested, inspected and registered to meet the standards of
ASME.
California Code: Unit may comply with California Code 462
(L) (2)/(M) (2). Specification/model label is on the side of the
tank on units that comply with California Code.
Cut-In Pressure: While the motor is off, air tank pressure
drops as you continue to use your accessory or air tool.
DUTY CYCLE
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 you turn on your air compressor
and it 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.”
U.L. Listed: Products with the U.L. mark are listed by Underwriters Laboratories, Inc. (U.L.). Samples of these products
have been evaluated by U.L. and meet the applicable U.L.
standards for safety.
This manufactured air compressor should be operated on not
more than a 50% duty cycle. This means an air compressor
that pumps air more than 50% of one hour
GENERAL INFORMATION
You have purchased an air compressor unit consisting of a 2
cylinder, single-stage air compressor pump, an air tank, and
associated controls and instruments.
This air compressor requires no oil. Now you can enjoy all the
benefits of having an air compressor without ever having to
purchase, add or change oil.
Your air compressor can be used for operating paint spray
is considered misuse, because the air compressor is undersized for the required air demand. Maximum compressor
pumping time per hour is 30 minutes.
guns, air tools, caulking guns, grease guns, air brushes,
sandblaster, or inflating tires and plastic toys, spraying weed
killers, insecticides, etc. An air pressure regulator is necessary for most of these applications.
Separate air transformers which combine the functions of air
regulation and/or moisture and dirt removal should be used
where applicable..
Separate air transformers which combine the functions of air
regulation and/or moisture and dirt removal should be used
where applicable.
ON-RECEIPT INSPECTIONON-RECEIPT INSPECTION
ON-RECEIPT INSPECTION
ON-RECEIPT INSPECTIONON-RECEIPT INSPECTION
DAMAGE:DAMAGE:
DAMAGE: Each air compressor outfit is carefully tested and
DAMAGE:DAMAGE:
checked before shipment. With improper handling, damage
may result in transit and cause problems in compressor
operation.
Immediately upon arrival, check equipment for both concealed
5 ENG
and visible damages to avoid expenses being incurred to
correct such problems. This should be done regardless of any
visible signs of damage to the shipping container. If this
product was shipped directly to you, report any damages to
carrier and arrange for inspection of goods immediately.
DESCRIPTION OF OPERATIONDESCRIPTION OF OPERATION
DESCRIPTION OF OPERATION
DESCRIPTION OF OPERATIONDESCRIPTION OF OPERATION
Drain Valve:Drain Valve:
Drain Valve: The drain valve is located at the base of the air
Drain Valve:Drain Valve:
tank and is used to drain condensation at the end of each use.
Motor Thermal Overload Protector:Motor Thermal Overload Protector:
Motor Thermal Overload Protector: The electric motor
Motor Thermal Overload Protector:Motor Thermal Overload Protector:
has an automatic thermal overload protector. If the motor
overheats for any reason, the thermal overload protector will
shut off the motor. The motor must be allowed to cool before
restarting.
ON/AUTO - OFF Switch:ON/AUTO - OFF Switch:
ON/AUTO - OFF Switch: Turn this switch ON to provide
ON/AUTO - OFF Switch:ON/AUTO - OFF Switch:
automatic power to the pressure switch and OFF to remove
power at the end of each use.
Air Intake Filter:Air Intake Filter:
Air Intake Filter: This filter is designed to clean air coming
Air Intake Filter:Air Intake Filter:
into the pump. This filter must always be clean and ventilation openings free from obstructions. See "Maintenance".
Air Compressor Pump:Air Compressor Pump:
Air Compressor Pump: To compress air, the piston moves
Air Compressor Pump:Air Compressor Pump:
up and down in the cylinder. On the downstroke, air is drawn
in through the air intake valves. The exhaust valve remains
closed. On the upstroke of the piston, air is compressed. The
intake valves close and compressed air is forced out through
the exhaust valve, into the outlet tube, through the check
valve and 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: Check Valve:
Check Valve: When the air compressor is operating, the
Check Valve: Check Valve:
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:Pressure Release Valve:
Pressure Release Valve: The pressure release valve
Pressure Release Valve: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. If the air is not released, the
motor will try to start, but will be unable to. 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 Switch:Pressure Switch:
Pressure Switch: The pressure switch automatically starts
Pressure Switch:Pressure Switch:
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:Safety Valve:
Safety Valve: If the pressure switch does not shut off the air
Safety Valve:Safety Valve:
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:Outlet Pressure Gauge:
Outlet Pressure Gauge: The outlet pressure gauge indi-
Outlet Pressure Gauge:Outlet Pressure Gauge:
cates the air pressure available at the outlet side of the
regulator. This pressure is controlled by the regulator and is
always less or equal to the tank pressure.
Tank Pressure Gauge: Tank Pressure Gauge:
Tank Pressure Gauge: The tank pressure gauge indicates
Tank Pressure Gauge: Tank Pressure Gauge:
the reserve air pressure in the tank.
Cooling System: 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.
INSTINST
INST
INSTINST
Removal of Shipping Boards and InstallationRemoval of Shipping Boards and Installation
Removal of Shipping Boards and Installation
Removal of Shipping Boards and InstallationRemoval of Shipping Boards and Installation
for (Stationary) Unitsfor (Stationary) Units
for (Stationary) Units
for (Stationary) Unitsfor (Stationary) Units
It may be necessary to brace or support one
side of the outfit when removing the shipping
boards because the air compressor will have a
tendency to tip.
1. Remove all packaging such that only the compressor on
the pallet remains. Remove and discard the (4) screws
and washers that hold the compressor to the pallet.
2. Stationary air compressors must be bolted to the floor.
Bolting holes are provided in the base feet. Mount the air
compressor on a solid, level foundation. Support compressor weight evenly on all four feet. Solid shims may be
used if necessary.
ALLAALLA
ALLA
ALLAALLA
TION AND BREAKTION AND BREAK
TION AND BREAK
TION AND BREAKTION AND BREAK
-IN PROCEDURES-IN PROCEDURES
-IN PROCEDURES
-IN PROCEDURES-IN PROCEDURES
EXCESSIVE VIBRATION CAN WEAKEN THE
AIR TANK AND CAUSE AN EXPLOSION. THE
COMPRESSOR MUST BE PROPERLY MOUNTED
AS ILLUSTRATED BELOW.
6 ENG
INSTINST
INST
INSTINST
Location of the Air CompressorLocation of the Air Compressor
Location of the Air Compressor
Location of the Air CompressorLocation of the Air Compressor
Locate the air compressor in a clean, dry and well ventilated
area. The air filter must be kept clear of obstructions which
could reduce air flow to the air compressor. 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 head and shroud are designed to
allow for proper cooling. If humidity is high, an air filter can
be installed on the air outlet adapter to remove excessive
moisture. Follow the instructions packaged with the air filter
for proper installation.
ALLAALLA
ALLA
ALLAALLA
TION AND BREAKTION AND BREAK
TION AND BREAK
TION AND BREAKTION AND BREAK
Lubrication and Oil
This unit needs no lubrication or oiling.
Extension Cords
To avoid voltage drop, power loss, and overheating to the
motor, use extra air hose instead of an extension cord. Low
voltage can cause damage to the motor.
If an extension cord must be used:
• do not use with any permanently mounted air compressor.
• use only a 3-wire extension cord that has a 3-blade
grounding plug and a 3-slot receptacle that will accept
the plug on the extension cord.
• make sure the extension cord is in good condition.
• the extension cord should be no longer than 50 feet.
• the minimum wire size is 12 gauge (AWG). (Wire size
increases as gauge number decreases. 10 AWG and
8 AWG may also be used. DO NOT USE 14 AWG or
16 AWG.)
-IN PROCEDURES-IN PROCEDURES
-IN PROCEDURES
-IN PROCEDURES-IN PROCEDURES
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.
IMPROPER GROUNDING CAN RESULT IN ELECTRICAL
SHOCK! ALL GROUNDING SHOULD BE PERFORMED BY
A LICENSED ELECTRICIAN IN ACCORDANCE WITH
NA TIONAL 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. The air compressor
can be grounded by the following method:
When hard wiring in an air compressor , use wiring that contains
a bare copper grounding wire. This wire must be connected
to the pressure switch at the grounding location provided.
This is located inside the pressure switch. The other end of
the wire must be connected to a ground at the fuse/circuit
breaker box in accordance with national and local electrical
codes.
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 an Authorized
Warranty Service Center or a licensed electrician.
Voltage and Circuit Protection
Refer to the specification chart for voltage and circuit
protection requirements of your compressor. Use only a fuse
or circuit breaker that is the same rating as the branch circuit
the air compressor is operated on. If the compressor is
connected to a circuit protected by fuses, use only dual
element time delay fuses.
Piping
Plastic or PVC pipe is not designed for use withPlastic or PVC pipe is not designed for use with
Plastic or PVC pipe is not designed for use with
Plastic or PVC pipe is not designed for use withPlastic or PVC pipe is not designed for use with
compressed air. Regardless of its indicated pres-compressed air. Regardless of its indicated pres-
compressed air. Regardless of its indicated pres-
compressed air. Regardless of its indicated pres-compressed air. Regardless of its indicated pressure rating, plastic pipe can burst from air pres-sure rating, plastic pipe can burst from air pres-
sure rating, plastic pipe can burst from air pres-
sure rating, plastic pipe can burst from air pres-sure rating, plastic pipe can burst from air pressure. Use only metal pipe for air distribution lines.sure. Use only metal pipe for air distribution lines.
sure. Use only metal pipe for air distribution lines.
sure. Use only metal pipe for air distribution lines.sure. Use only metal pipe for air distribution lines.
If a pipe line is necessary, 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.
It is recommended that a flexible coupling be installed
between the air discharge valve outlet and main air distribution line to allow for vibration.
Additional Regulators and ControlsAdditional Regulators and Controls
Additional Regulators and Controls
Additional Regulators and ControlsAdditional Regulators and Controls
Since the air tank pressure is usually greater than that which
is needed, a separate regulator is usually employed to control
the air pressure ahead of any individual air driven device.
Break-in ProceduresBreak-in Procedures
Break-in Procedures
Break-in ProceduresBreak-in Procedures
Serious damage may result if the followingSerious damage may result if the following
Serious damage may result if the following
Serious damage may result if the followingSerious damage may result if the following
break-in instructions are not closely followed.break-in instructions are not closely followed.
break-in instructions are not closely followed.
break-in instructions are not closely followed.break-in instructions are not closely followed.
This procedure is required:
1. Before the air compressor is put into service. (Before the
hose is installed.)
2. When the check valve is replaced.
3. When a complete compressor pump is replaced.
a. Set the pressure switch lever to the "OFF" position.
b. Plug the power cord into the correct branch circuit
receptacle.
c. Turn the regulator clockwise opening it fully, to
prevent air pressure build-up in the tank.
d. Move the pressure switch lever to "ON/AUTO". The
compressor will start.
e. Run the compressor for 15 minutes. Make sure the
regulator is open and there is no tank pressure buildup.
f. After 15 minutes, close the regulator by turning it
counterclockwise. The air receiver will fill to cut-out
pressure and the motor will stop. The compressor is
now ready for use.
7 ENG
OPERATING PROCEDURESOPERATING PROCEDURES
OPERATING PROCEDURES
OPERATING PROCEDURESOPERATING PROCEDURES
Daily Start-Up ChecklistDaily Start-Up Checklist
Daily Start-Up Checklist
Daily Start-Up ChecklistDaily Start-Up Checklist
1. Before attaching air hose or accessories, make sure the
ON/AUTO lever is set to “OFF” and the air regulator or
globe valve is closed.
2. Attach hose and accessories.
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.
Compressed air from the outfit may contain
water condensation. Do not spray unfiltered
air at an item that could be damaged. Some
air operated tools or devices may require
filtered air. Read the instructions for the air
tool or device.
3. Check the manufacturer’s maximum pressure rating for
air tools and accessories.The regulator outlet pressure
must never exceed the maximum pressure rating. If your
compressor is not supplied with a regulator with gauge,
install one before using accessories.
4. Turn the ON/AUTO lever to “AUTO” and allow tank
pressure to build. Motor will stop when tank pressure
reaches “cut-out” pressure.
5. Open the globe valve by turning it counter clockwise.
Open the regulator by turning it clockwise. Adjust the
regulator to the correct pressure setting. Your
compressor is ready for use.
6. Always operate the air compressor in well-ventilated
areas; free of gasoline or other solvent vapors. Do not
operate the compressor near the spray area.
When you are finished:
7. Set the “ON/AUTO” lever to “OFF”.
8. Turn the regulator or globe valve counterclockwise and
set the outlet pressure to zero.
9. Remove the air tool or accessory.
10. Open the regulator and allow the air to slowly bleed from
the tank. Close the regulator tank and/or globe valve when
tank pressure is approximately 20 psi.
11. Drain water from air tank by opening drain valve on
bottom of tank.
WATER WILL CONDENSE IN THE AIR TANK. IF NOTWATER WILL CONDENSE IN THE AIR TANK. IF NOT
WATER WILL CONDENSE IN THE AIR TANK. IF NOT
WATER WILL CONDENSE IN THE AIR TANK. IF NOTWATER WILL CONDENSE IN THE AIR TANK. IF NOT
DRAINED, WATER WILL CORRODE AND WEAKEN THEDRAINED, WATER WILL CORRODE AND WEAKEN THE
DRAINED, WATER WILL CORRODE AND WEAKEN THE
DRAINED, WATER WILL CORRODE AND WEAKEN THEDRAINED, WATER WILL CORRODE AND WEAKEN THE
AIR TANK CAUSING A RISK OF AIR TANK RUPTURE.AIR TANK CAUSING A RISK OF AIR TANK RUPTURE.
AIR TANK CAUSING A RISK OF AIR TANK RUPTURE.
AIR TANK CAUSING A RISK OF AIR TANK RUPTURE.AIR TANK CAUSING A RISK OF AIR TANK RUPTURE.
12. After the water has been drained, close the drain valve.
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.
MAINTENANCEMAINTENANCE
MAINTENANCE
MAINTENANCEMAINTENANCE
UNIT CYCLES AUTOMATICALLY WHEN POWER IS ON. WHEN DOING MAINTENANCE, YOU MAY BE EXPOSED TO
VOLTAGE SOURCES, COMPRESSED AIR OR MOVING PARTS. PERSONAL INJURIES CAN OCCUR. BEFORE
PERFORMING ANY MAINTENANCE OR REPAIR, DISCONNECT POWER SOURCE FROM THE COMPRESSOR AND
BLEED OFF ALL AIR PRESSURE.
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE DONE BY
QUALIFIED SERVICE PERSONNEL.
To ensure efficient operation and longer life of the air compressor outfit, a routine maintenance schedule should be prepared
and followed. The following routine maintenance schedule is geared to an outfit in 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 outfits in an extremely
dirty and/or hostile environment will require a greater frequency of all maintenance checks.
ROUTINE MAINTENANCE SCHEDULEROUTINE MAINTENANCE SCHEDULE
ROUTINE MAINTENANCE SCHEDULE
ROUTINE MAINTENANCE SCHEDULEROUTINE MAINTENANCE SCHEDULE
Daily:Daily:
Daily:
Daily:Daily:
1. Drain water from the air tank, any moisture separators
or transformers.
2. Check for any unusual noise and/or vibration.
3. Manually check safety valve to make sure of proper
operation.
4. Inspect air filter, replace if necessary.
5. Inspect air lines and fittings for leaks; correct as
necessary.
Each Year of Operation or if a Problem is Sus-Each Year of Operation or if a Problem is Sus-
Each Year of Operation or if a Problem is Sus-
Each Year of Operation or if a Problem is Sus-Each Year of Operation or if a Problem is Suspected:pected:
pected:
pected:pected:
Check condition of air compressor pump intake and exhaust
valves. Replace if damaged or worn out.
8 ENG
SERVICE INSTRUCTIONSSERVICE INSTRUCTIONS
SERVICE INSTRUCTIONS
SERVICE INSTRUCTIONSSERVICE INSTRUCTIONS
Air Filter - Inspection and ReplacementAir Filter - Inspection and Replacement
Air Filter - Inspection and Replacement
Air Filter - Inspection and ReplacementAir Filter - Inspection and Replacement
Keep the air filter clean at all times. Do not operate the
compressor with the air filter removed.
A dirty air filter will not allow the compressor to operate at full
capacity. Before you use the compressor, check the air filter
to be sure it is clean.
If it is dirty, simply pull it out. You may wash it with a mild
detergent and warm water, or replace it.
Hot surfaces. Risk of burn. Compressor
heads are exposed when filter cover is
removed. Allow compressor to cool prior to
servicing.
Motor
The motor has an automatic reset thermal overload protector. If the motor overheats for any reason, the overload
protector will shut off the motor. The motor must be allowed
to cool down before restarting. The compressor will automatically restart after the motor cools.
If the overload protector shuts the motor off frequently,
check for a possible voltage problem. Low voltage can also
be suspected when:
1. The motor does not get up to full power or speed.
2. Fuses blow out when starting the motor; lights dim and
remain dim when motor is started and/or is running.
Units With External Brass Check Valve
Replacement
Filter
Safety Valve - Inspection
IF THE SAFETY VALVE DOES NOT WORK PROP-IF THE SAFETY VALVE DOES NOT WORK PROP-
IF THE SAFETY VALVE DOES NOT WORK PROP-
IF THE SAFETY VALVE DOES NOT WORK PROP-IF THE SAFETY VALVE DOES NOT WORK PROPERLY, OVER-PRESSURIZATION MAY OCCUR,ERLY, OVER-PRESSURIZATION MAY OCCUR,
ERLY, OVER-PRESSURIZATION MAY OCCUR,
ERLY, OVER-PRESSURIZATION MAY OCCUR,ERLY, OVER-PRESSURIZATION MAY OCCUR,
CAUSING AIR TANK RUPTURE OR AN EXPLO-CAUSING AIR TANK RUPTURE OR AN EXPLO-
CAUSING AIR TANK RUPTURE OR AN EXPLO-
CAUSING AIR TANK RUPTURE OR AN EXPLO-CAUSING AIR TANK RUPTURE OR AN EXPLOSION. OCCASIONALLY PULL THE RING ON THESION. OCCASIONALLY PULL THE RING ON THE
SION. OCCASIONALLY PULL THE RING ON THE
SION. OCCASIONALLY PULL THE RING ON THESION. OCCASIONALLY PULL THE RING ON THE
SAFETY VALVE TO MAKE SURE THAT THE SAFETYSAFETY VALVE TO MAKE SURE THAT THE SAFETY
SAFETY VALVE TO MAKE SURE THAT THE SAFETY
SAFETY VALVE TO MAKE SURE THAT THE SAFETYSAFETY VALVE TO MAKE SURE THAT THE SAFETY
VALVE OPERATES FREELY. IF THE VALVE ISVALVE OPERATES FREELY. IF THE VALVE IS
VALVE OPERATES FREELY. IF THE VALVE IS
VALVE OPERATES FREELY. IF THE VALVE ISVALVE OPERATES FREELY. IF THE VALVE IS
STUCK OR DOES NOT OPERATE SMOOTHLY, ITSTUCK OR DOES NOT OPERATE SMOOTHLY, IT
STUCK OR DOES NOT OPERATE SMOOTHLY, IT
STUCK OR DOES NOT OPERATE SMOOTHLY, ITSTUCK OR DOES NOT OPERATE SMOOTHLY, IT
MUST BE REPLACED WITH THE SAME TYPE OFMUST BE REPLACED WITH THE SAME TYPE OF
MUST BE REPLACED WITH THE SAME TYPE OF
MUST BE REPLACED WITH THE SAME TYPE OFMUST BE REPLACED WITH THE SAME TYPE OF
VALVE.VALVE.
VALVE.
VALVE.VALVE.
STORAGE
Before you store the air compressor, make sure you do the
following:
1. Review the “Maintenance” and "Operating Procedures"
sections and perform maintenance as necessary. Be
sure to drain water from the air tank.
1. Release all air pressure from air tank and disconnect
power from outfit.
2. Remove shroud.
3. Loosen the top and bottom nuts and remove the outlet
tube.
4. Remove the pressure release tube and fitting.
5. Unscrew the check valve (turn counterclockwise) using
a socket wrench.
6. Check that the valve disc moves freely inside the check
valve and that the spring holds the disc in the upper,
closed position. The check valve may be cleaned with
a strong solvent.
7. Apply sealant to the check valve threads. Reinstall the
check valve (turn clockwise).
8. Replace the pressure release tube and fitting.
9. Replace the outlet tube and tighten top and bottom nuts.
10. Replace the shroud.
2. Protect the electrical cord and air hose from damage
(such as being stepped on or run over). Wind them
loosely around the compressor handle.
3. Store the air compressor in a clean and dry location.
9 ENG
TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDE
TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE
PERFORMING REPAIRS MAY EXPOSE VOLTAGE SOURCES, MOVING PARTS OR COMPRESSED AIR SOURCES.
PERSONAL INJURY MAY OCCUR. PRIOR TO ATTEMPTING ANY REPAIRS, DISCONNECT POWER SOURCE FROM THE
COMPRESSOR AND BLEED OFF TANK AIR PRESSURE.
PROBLEM CAUSE
Excessive tank pressure - safety
valve pops off.
Air leaks at fittings.
Air leaks at or inside check valve.
Air leaks at pressure switch
release valve.
Air leaks in air tank or at air tank
welds.
Air leaks between head and valve
plate.
Pressure reading on the regulated pressure gauge drops when
an accessory is used.
Air leak from safety valve.
Knocking Noise.
Pressure switch does not shut off
motor when compressor reaches
“cut-out” pressure.
Pressure switch “cut-out” too high.
Tube fittings are not tight enough.
Defective or dirty check valve.
Defective pressure switch release
valve.
Defective check valve.
Defective air tank.
Leaking o-ring.
It is normal for “some” pressure drop
to occur.
Possible defect in safety valve.
Defective check valve.
CORRECTION
Move the pressure switch lever to the “OFF” position. If the outfit doesn’t shut off, unplug. If the
electrical contacts are welded together, replace
the pressure switch.
Replace pressure switch.
Tighten fittings where air can be heard escaping.
Check fittings with soapy water solution. DO NOT
OVER-TIGHTEN.
A defective check valve results in a constant air
leak at the pressure release valve when there is
pressure in the tank and the compressor is shut off.
Drain tank then remove and clean or replace
check valve. DO NOT OVER-TIGHTEN.
Remove and replace the release valve.
A defective check valve results in a constant air
leak at the pressure release valve when there is
pressure in the tank and the compressor is shut off.
Drain tank then remove and clean or replace
check valve. DO NOT OVER-TIGHTEN.
DO NOT DRILL INTO, WELD OR OTHERWISEDO NOT DRILL INTO, WELD OR OTHERWISE
DO NOT DRILL INTO, WELD OR OTHERWISE
DO NOT DRILL INTO, WELD OR OTHERWISEDO NOT DRILL INTO, WELD OR OTHERWISE
MODIFY AIR TANK OR IT WILL WEAKEN.MODIFY AIR TANK OR IT WILL WEAKEN.
MODIFY AIR TANK OR IT WILL WEAKEN.
MODIFY AIR TANK OR IT WILL WEAKEN.MODIFY AIR TANK OR IT WILL WEAKEN.
THE TANK CAN RUPTURE OR EXPLODE.THE TANK CAN RUPTURE OR EXPLODE.
THE TANK CAN RUPTURE OR EXPLODE.
THE TANK CAN RUPTURE OR EXPLODE.THE TANK CAN RUPTURE OR EXPLODE.
TANK MUST BE REPLACED.TANK MUST BE REPLACED.
TANK MUST BE REPLACED.
TANK MUST BE REPLACED.TANK MUST BE REPLACED.
Torque head screws to 8 ft. lbs. If this does not stop
leak, replace o-ring.
If there is an excessive amount of pressure drop
when the accessory is used, adjust the regulator
following the instructions on page 6.
NOTE:
Adjust the regulated pressure under flow
conditions (while accessory is being used).
Operate safety valve manually by pulling on ring.
If valve still leaks, it should be replaced.
Remove and clean, or replace.
Compressor is not supplying
enough air to operate accessories.
Prolonged excessive use of air.
Compressor is not large enough for air
requirement.
Restricted air intake filter.
Hole in hose.
Check valve restricted.
Air leaks.
10 ENG
Decrease amount of air usage.
Check the accessory air requirement. If it is higher
than the SCFM or pressure supplied by your air
compressor, you need a larger compressor.
Clean or replace air intake filter. Do not operate
the air compressor with the filter removed. See
page 9.
Check and replace if required.
Remove and clean, or replace.
Tighten fittings. (See Air Leaks Section of Trou-
bleshooting Guide.)
PROBLEM
Motor will not run or restart.
CAUSE
Motor overload protection switch has
tripped.
Tank pressure exceeds pressure
switch “cut-in” pressure.
Wrong gauge wire or length of extension cord.
Check valve stuck open.
Loose electrical connections.
Possible defective motor or capacitor.
Paint spray on internal motor parts.
Fuse blown, circuit breaker tripped.
CORRECTION
Let motor cool off and overload switch will automatically reset.
Motor will start automatically when tank pressure
drops below “cut-in” pressure of pressure switch.
Check for proper gauge wire and cord length.
Remove and clean, or replace.
Check wiring connection inside pressure switch
and terminal box area.
Inspect or replace, if necessary.
Inspect or replace, if necessary. Do not operate the
compressor in the paint spray area. See flammable
vapor warning.
1. Check fuse box for blown fuse and replace, if
necessary. Reset circuit breaker. Do not use a
fuse or circuit breaker with higher rating than
that specified for your particular branch circuit.
2. Check for proper fuse; only “Fusetron” type T
fuses are acceptable.
3. Check for low voltage conditions and/or proper
extension cord.
4. Disconnect the other electrical appliances
from circuit or operate the compressor on its
own branch circuit.
Regulator knob has continuous
air leak. Regulator will not shut
off air outlet.
Pressure release valve on pressure
switch has not unloaded head pressure.
Damaged regulator.
Bleed the line by pushing the lever on the pressure
switch to the “off” position; if the valve does not
open, replace it.
Replace regulator.
11 ENG
PP
ARTS LISTINGARTS LISTING
P
ARTS LISTING
PP
ARTS LISTINGARTS LISTING
KEY NO.
1
2
3
5
6
7
8
9
10
12
13
14
15
16
17
19
PART NUMBER
DAC-243
DAC-244
ACG-408
ACG-13
ACG-12
SSF-554
AC-0242
AC-0099
SSP-7813
SSP-7821-1
SSG-3105
CAC-4290-3
SS-8553
SSP-7811
AC-0215
CAC-4221-3
DESCRIPTION
Shroud, Rear
Shroud, Front
Fastener Assembly
(3 used: Torque 33-38 in.-lbs.)
Cover, Intake Muffler
Filter Element
Screw, #10-14 x 2.5 Pan Head
(2 used)
Outlet Tube
Crossover Tube
Nut/Sleeve Assy.
Nut Brass Compression (3 used)
Silicone Sleeve (3 used)
Check Valve
Connector Body
Nut/Sleeve Assy. (2 used)
Pressure Relief Tube
Pressure Switch
KEY NO.
20
21
22
23
24
25
26
27
28
30
PART NUMBER
SSW-7367
GA-360
97503734
SS-2072-1
SSV-812
AC-0217
ACG-18
SSF-990
ACG-19
SS-2707
DESCRIPTION
Bushing Strain Relief
Gauge
Safety Valve
Nipple 3/8" x 1.5"
Vavlve Globe 200P91
Manifold
Cup, Saddle Mount (2 used)
Screw, 1/4 - 2 ounc - 2A
THD Forming Mount (2 used)
Isolator (3 used)
Drain Valve
12 ENG
PP
ARTS LISTINGARTS LISTING
P
ARTS LISTING
PP
ARTS LISTINGARTS LISTING
KEY
NO. PART NUMBER DESCRIPTION
1 MO-9074 Motor
* +
2 ----- Sleeve, Cylinder (2 used)
*
3 ----- Connecting Rod (2 used)
*+
4 ----- Compression Ring (2 used)
*
5 ACG-29 Connecting Rod Cap (2 used)
*+
6 SSF-3158-1 Screw, 10-24 x .75 (2 used)
*
7 SSG-8156 O-ring (2 used)
8 AC-0032 V alve Plate Assembly (2 used)
*
9 ACG-45 O-ring, Perm Lube Head (2 used)
10 AC-0037 Head, Right
11 AC-0038 Head, Left
12 SSF-927 Screw, THD Forming 1/4-20 X 1.25
(8 used: Torque 7-10 ft.-lbs.)
13 ACG-11 Muffler, Intake (2 used)
14 ACG-8 Pin, Eccentric
15 ACG-6 Counter Balance, Inner
16 ACG-9 Washer
17 ACG-7 Counter Balance, Outer
18 ACG-23 Nut (Torque 85-100 ft.lbs.)
19 ACG-22 Fan
20 39124607 Screw, Self Tap 1/4 x 5/8
(Torque 75-90 in.-lbs.)
* Keys 2 , 3, 4, 5, 6, 7, & 9 can only be purchased in Connecting
Rod Kit KK-5081.
+ Keys 2, 4, and 6 can be purchased in Cylinder\Compression
Ring Kit K-0058.
TORQUEKey #
12
18
20
*TORQUE WRENCH MUST BE USED
7 to 10 FT. LBS.
85 to 100 FT. LBS.
75 to 90 IN. LBS.
13 ENG
OWNERS MANUAL FOR
Permantly Lubricated Twin Cylinder Air Compr essor
Call our Toll Free Number 1-800-888-2468, Ext 2, then Ext 1, to
obtain the location of the nearest Authorized Service Center for
ordering repair parts and for warranty r epairs. 24 hours a day, 7 days
a week.
When ordering repair parts fr om your local Authorized Service Center ,
always give the following information:
• Model number of your product
• Part number and description of the item you
wish to purchase
WARRANTY
This product is covered by the
DeVilbiss one year limited warranty .
The warranty can be found in the
General Manual or is available upon
request.
Attach Sales Receipt Here
Retain Original Sales Receipt as
Proof of Purchase for Warranty
Repair Work.
DeVilbiss Air Power Company • 213 Industrial Dr. • Jackson, TN 38301
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