DeWalt DeVILBISS User Manual
Air Compressor
Oil Lubricated ● Single Stage● HorizontalPortable
OPERATOR’S MANUAL
SAFETY ● ASSEMBLY
●
OPERATION ● MAINTENANCE
●
STORAGE
●
TROUBLESHOOTING ● ESPAÑOL● FRANÇAIS
D23766 Rev. 1 1/4/04
Read Operator’s Manual. Do not operate equipment until you have read
this Operator’s Manual for Safety, Assembly, Operation, and
Maintenance Instructions
.
Register your product on line at www.devap.com
2- ENG
D23766
TABLE OF CONTENTS
Safety Guidelines-Definitions . . . .2
Important Safety Instructions . .2-7
On-Receipt Inspection . . . . . . . . .8
Glossary . . . . . . . . . . . . . . . . . . . . .8
Duty Cycle . . . . . . . . . . . . . . . . . . .8
Accessories . . . . . . . . . . . . . . . . . .8
Assembly . . . . . . . . . . . . . . . . . .9-11
Installation . . . . . . . . . . . . . . .12-14
SAFETY GUIDELINES - DEFINITIONS
Indicates an
imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a
potentially
hazardous situation which, if not
avoided, could
result in death or
serious injury.
Indicates a
potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury.
Used without the
safety alert symbol
indicates a potentially hazardous
situation which, if not avoided, may
result in pr
operty damage.
This manual contains information that is important for you to know and
understand. This information relates to protecting YOUR SAFETY and
PREVENTING EQUIPMENT PROBLEMS. To help you recognize this
information, we use the symbols below. Please read the manual and pay
attention to these symbols.
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.
Operation . . . . . . . . . . . . . . . .15-17
Maintenance . . . . . . . . . . . . . .18-20
Service and Adjustments . . .21-23
Storage . . . . . . . . . . . . . . . . . . . . .24
Troubleshooting Guide . . . . .25-28
Warranty . . . . . . . . . . . . . . . . . . . .30
Español . . . . . . . . . . . . . . . . . .31-60
Français . . . . . . . . . . . . . . . . .61-92
3- ENG
D23766
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
How To Prevent It
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.
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.
4- ENG
D23766
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.
How To Prevent It
What Could Happen
WARNING: Risk from Flying Objects
The compressed air stream can cause
soft tissue damage to exposed skin
and can propel dirt, chips, loose
particles, and small objects at high
speed, resulting in property damage or
personal injury.
Always wear ANSI Z87.1 approved 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.
HAZARD
HAZARD
Drain tank daily or after each use. If
tank develops a leak, replace it
immediately with a new tank or replace
the entire compressor.
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.
Never drill into, weld, or make any
modifications to the tank or its
attachments.
Excessive vibration can weaken the
air tank and cause rupture or
explosion
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.
A
TTACHMENTS & 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.
How To Prevent It
What Could Happen
5- ENG
D23766
WARNING: Risk to Breathing
WARNING: Risk of Electrical Shock
HAZARD
HAZARD
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.
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.
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.
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.
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
6- ENG
D23766
WARNING: Risk of Burns
Touching exposed metal such as the
compressor head or outlet tubes, can
result in serious burns.
Never touch any exposed metal parts
on compressor during or 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.
WARNING: Risk from Moving Parts
Never operate the compressor with
guards or covers which are damaged or
removed.
Moving parts such as the pulley,
flywheel, and belt can cause serious
injury if they come into contact with you
or your clothing.
WARNING: Risk of Falling
A portable compressor can fall from a
table, workbench, or roof causing
damage to the compressor and could
result in serious injury or death to the
operator.
Always operate compressor in a stable
secure position to prevent accidental
movement of the unit. Never operate
compressor on a roof or other elevated
position. Use additional air hose to
reach high locations.
HAZARD
HAZARD
HAZARD
Any repairs required on this product
should be performed by authorized
service center personnel.
Attempting to operate compressor with
damaged or missing parts or
attempting to repair compressor with
protective shrouds removed can expose
you to moving parts and can result in
serious injury.
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
7- ENG
D23766
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.
WARNING: Risk of Unsafe Operation
Unsafe operation of your air compressor
could lead to serious injury or death to
you or others.
HAZARD
WARNING: Risk of Serious Injury or Property Damage When
Transporting Compressor
Oil can leak or spill and could result in
fire or breathing hazard; serious injury or
death can result. oil leaks will damage
carpet, paint or other surfaces in
vehicles or trailers.
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.
(Fire, Inhalation, Damage to Vehicle Surfaces)
HAZARD
SAVE THESE INSTRUCTIONS
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
8- ENG
D23766
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.
DUTY CYCLE
Air compressors should be operated
on not more than a 50% duty cycle.
This means an air compressor that
pumps air more than 50% of one
hour is considered misuse, because
Accessories for this unit are available at the store the unit was purchased.
ACCESSORIES
NOTE: Photographs and line drawings used in this manual are for
reference only and do not represent a specific model.
ON-RECEIPT INSPECTION
Each air compressor unit is carefully
checked before shipment. With
improper handling, damage may
result in transit and cause problems
in air compressor operation.
Immediately upon arrival, check
equipment for both concealed 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.
Report any damages to carrier and
arrange for inspection of goods
immediately.
For the location or a listing of the
nearest Authorized Warranty Service
Center, call our toll free number at
1-800-888-2468.
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.
the air compressor is undersized for
the required air demand. Maximum
compressor pumping time per hour is
30 minutes.
9- ENG
D23766
3. Slowly push the open ends of
the handle onto both tabs at the
same time. Continue pushing the
handle into the saddle until the
holes on the side of the saddle
and handle are in line.
4. Guide the straight end of each
retaining clip through the saddle
hole and both handle holes.
5. Rotate each retaining clip and
press down until it snaps into
place over the handle.
Unpacking
1. Remove unit from carton and
discard all packaging. NOTE:
Save all parts bags.
To Install Handle
The wheels and
handle do not
provide adequate clearance,
stability, or support for pulling the
unit up and down stairs or steps.
The unit must be lifted or pushed
up a ramp. Do not lift the unit by
the manifold assembly, the unit
could be damaged.
1. (if equipped) To make
installation easier, submerge
handle grip into warm soapy
water. Remove handle grip from
soapy water and slide onto
handle.
2. Insert the open end of the handle
under the saddle. Before
attaching handle, you may have
to pull the open ends of the
handle apart so they fit tightly
against the side of the saddle.
Looking in from the open end of
the saddle, position the handle
toward the two bent tabs, on the
inside walls of the saddle.
ASSEMBLY
Tools Required for Assembly
1 - 9/16" socket or open end wrench
1 - 1/2" socket or open end wrench
10- ENG
D23766
6. If the handle has excessive
movement, it is improperly
installed. Check the following.
A. Are both tabs inside the
handle (Step #3)?
B. Does each clip pass through
both the saddle and handle
(Step #4)?
Assemble Rubber Strip
(if equipped)
1. Remove the protective paper
strip from the adhesive-backed
rubber foot strip. Attach the
rubber foot strip to the bottom of
the air tank leg. Press firmly into
place.
Assemble Rubber Feet
(if equipped)
1. Attach rubber feet with the
screws, washers and nuts
provided as shown.
2. Tighten securely.
Screw
Nut
Flat
Washer
Rubber Foot
Rubber
Foot Strip
Tank Leg
To Assemble Wheels
It will be necessary
to brace or support
one side of the unit when installing
the wheels because the
compressor will have a tendency to
tip.
1. Attach wheels with shoulder
bolts and nuts as shown.
2. Tighten securely. NOTE: The unit
will sit level if the wheels are
properly installed.
The wheels and
handle do not
provide adequate clearance,
stability or support for pulling the
unit up and down stairs or steps.
The unit must be lifted, or pushed
up a ramp.
Wheel
Shoulder Bolt
Nut
To Add Oil To Pump
Compressors are
shipped without
oil. A small amount of oil may be
present in the pump upon receipt
of the air compressor. This is due
to plant testing and does not mean
the pump contains oil. Do not
attempt to operate this air
compressor without first adding oil
to the crankcase. Serious damage
can result from even limited
operation unless filled with oil and
broken in correctly. Make sure to
closely follow initial start-up
procedures.
11- ENG
D23766
NOTE: Do not allow oil to be lower
than 3/8" (6 threads) from the top at
any time. When filling the crankcase,
the oil flows very slowly into the
pump. If the oil is added too quickly,
it will overflow and appear to be full.
Slowly fill crankcase to the top of the
fill hole. NOTE: Crankcase oil
capacity is approximately 16 fluid
ounces (473.2 ml).
3. Replace oil fill plug (A).
Multi-Viscosity
motor oils, like 10W
30, should not be used in an air
compressor. They leave carbon
deposits on critical components,
thus reducing performance and
compressor life. Use air
compressor oil only.
NOTE: Oil is included with some
units. If oil is not included, use an oil
specifically formulated for use in an
air compressor, such as Porter-Cable
PAS1 air compressor oil. Oil may be
found at the store where the air
compressor was purchased.
1. Place unit on a level surface.
Drain tank to
release air
pressure before removing the oil fill
cap or oil drain plug.
2. Remove oil fill plug (A) and slowly
add a compressor oil until it is
even with the top of the oil fill
hole.
A
12- ENG
D23766
Extension Cords
Use extra air hose instead of an
extension cord to avoid voltage drop
and power loss to the motor, and to
prevent overheating.
If an extension cord must be used, be
sure it is:
• a 3-wire extension cord that has
a 3-blade grounding plug, and a
3-slot receptacle that will accept
the plug on the product
• in good condition
• no longer than 50 feet
• 12 gauge (AWG) or larger. (Wire
size increases as gauge number
decreases. 10 AWG and 8 AWG
may also be used. DO NOT USE
14 OR 16 AWG.)
INSTALLATION
GROUNDING INSTRUCTIONS
RISK OF
ELECTRICAL
SHOCK. In the event of a short
circuit, grounding reduces the risk
of shock by providing an escape
wire for the electric current. This
air compressor must be properly
grounded.
The portable air compressor is
equipped with a cord having a
grounding wire with an appropriate
grounding plug (see following
illustrations).
1. The cord set and plug with this
unit contains a grounding pin.
This plug MUST be used with a
grounded outlet.
HOW TO SET UP YOUR
UNIT
Location of the Air Compressor
G
Locate the air compressor in a
clean, dry, and well ventilated
area.
G
The air compressor should be
located at least 12" away from
the wall or other obstructions
that will interfere with the flow of
air.
G
The air filter and flywheel must
be kept clear of obstructions
which could reduce air flow to
the air compressor.
G
The air compressor requires fresh
air flow for proper cooling. DO
NOT ALLOW THE
COMPRESSOR TO GET WET.
Grounding Pin
Grounded
Outlets
Plug
IMPORTANT: The outlet being used
must be installed and grounded in
accordance with all local codes and
ordinances.
2. Make sure the outlet being used
has the same configuration as
the grounded plug. DO NOT
USE AN ADAPTER. See
illustration.
3. Inspect the plug and cord before
each use. Do not use if there are
signs of damage.
4. If these grounding instructions
are not completely understood,
or if in doubt as to whether the
compressor is properly
grounded, have the installation
checked by a qualified
electrician.
IMPROPER
GROUNDING CAN
RESULT IN ELECTRICAL SHOCK.
Do not modify the plug provided. If
it does not fit the available outlet, a
correct outlet should be installed
by a qualified electrician.
Repairs to the cord set or plug
MUST be made by a qualified
electrician.
13- ENG
D23766
Voltage and Circuit Protection
Refer to the Parts Manual for the
voltage and minimum branch circuit
requirements.
Certain air compressors can be
operated on a 15 amp circuit if the
following conditions are met.
1. Voltage supply through branch
circuit is 15 amps.
2. Circuit is not used to supply any
other electrical needs (lights,
appliances, etc.).
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 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
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.
120/240 Dual Voltage Motor
This model has a dual voltage motor,
120 and 240 volt. It is wired for 120
volt but can be converted to 240 volt
operation. Instructions for connecting
the motor for operation at 240 volt
can be found printed on the label
attached to the side of the motor.
When converting to
240V operation, the
attached three-prong 120V cord
assembly must be replaced with a
three-pronged 240V cord assembly
(K-0080) that can be purchased
through a Sears Service Center.
120 Volt Plug
240 Volt Plug
14- ENG
D23766
• 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.
AIR FLOW
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.
LUBRICATOR
MOISTURE
SEPARATOR
AND TRAP
DIRT
LEG
FEEDER LINES SLOPE
WITH AIR FLOW
REGULATOR
DRAIN
TRAP
AIR USAGE
LINES
DIRT
LEG
AIR FLOW
FILTER
FLEXIBLE
COUPLING
AIR DISCHARGE
VALVE
DRAIN
LEGS
DRAIN
TRAPS
REGULATOR
COMPRESSOR
LUBRICATOR
AIR
TYPICAL COMPRESSED
AIR DISTRIBUTION SYSTEM
DRAIN COCK
VALVE
of the regulator. This pressure is
controlled by the regulator and is
always less than or equal to the tank
pressure.
Tank Pressure Gauge: The tank
pressure gauge indicates the reserve
air pressure in the tank.
Regulator: Controls the air pressure
shown on the outlet pressure gauge.
Pull the knob out and turn clockwise
to increase pressure and
counterclockwise to decrease
pressure. When the desired pressure
is reached push knob in to lock in
place.
Drain Valve: The drain valve is
located at the base of the air tank
and is used to drain condensation at
the end of each use.
15- ENG
D23766
Description of Operation
Become familiar with these controls
before operating the unit.
On/Auto/Off Switch: Turn this switch
ON to provide automatic power to the
pressure switch and OFF to remove
power at the end of each use.
Pressure Switch: The pressure
switch automatically starts the motor
when the air tank pressure drops
below the factory set "cut-in"
pressure. It stops the motor when the
air tank pressure reaches the factory
set "cut-out" pressure.
Safety Valve: If the pressure switch
does not shut off the air compressor
at its "cut-out" pressure setting, the
safety valve will protect against high
pressure by "popping out" at its
factory set pressure (slightly higher
than the pressure switch "cut-out"
setting).
Outlet Pressure Gauge: The outlet
pressure gauge indicates the air
pressure available at the outlet side
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.
Regulator
On/Auto/Off
Switch
Safety
Valve
Outlet
Pressure Gauge
Pressure
Switch
Drain
Valve
Tank
Pressure Gauge
Quick
Connect
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.
Check Valve: When the air
compressor is operating, the check
valve is "open", allowing compressed
air to enter the air tank. When the air
compressor reaches "cut-out"
pressure, the check valve "closes",
allowing air pressure to remain inside
the air tank.
Pressure Release Valve: The
pressure release valve located on the
side of the pressure switch, is
designed to automatically release
compressed air from the compressor
head and the outlet tube when the air
compressor reaches "cut-out"
pressure or is shut off. The pressure
release valve allows the motor to
restart freely. When the motor stops
running, air will be heard escaping
from this valve for a few seconds. No
air should be heard leaking when the
motor is running, or continuous
leaking after unit reaches "cut-out"
pressure.
16- ENG
D23766
Pressure
Release
Valve
Check Valve
Before Starting
Break-in instructions
Serious damage
may result if the
following break-in instructions are
not closely followed.
This procedure is required before the
air compressor is put into service and
when the check valve or a complete
compressor pump has been
replaced.
1. Make sure the On/Auto/Off lever
is in the "Off" position.
NOTE: If quick connect is installed,
pull coupler back until it clicks to
prevent air from escaping through the
quick connect.
2. Check oil level in pump. See
"Oil" paragraph in the
"Maintenance" section for
instructions.
3.
Plug the power cord into the
correct branch circuit receptacle.
(Refer to Voltage and Circuit
Protection paragraph in the
Installation section of this
manual.)
4. Open the drain valve fully
(counter-clockwise) to permit air
to escape and prevent air
pressure build up in the air tank
during the break-in period.
5. Move the On/Auto/Off lever to
"On/Auto" position. The
compressor will start.
6. Run the compressor for 20
How to Use Your Unit
How to Stop:
1. Set the On/Auto/Off lever to
"Off".
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".
17- ENG
D23766
How to Start:
1. Turn the On/Auto/Off lever to
"On/Auto" and allow tank
pressure to build. Motor will
stop when tank pressure reaches
"cut-out" pressure.
2. Pull the regulator knob out and
turn clockwise to increase
pressure. When the desired
pressure is reached push knob in
to lock in place. The compressor
is ready for use.
NOTE: Always operate the air
compressor in well-ventilated areas
free of gasoline or other combustible
vapors. If the compressor is being
used to operate a sprayer DO NOT
place near the spray area.
Before Each Start-Up:
1. Place On/Auto/Off lever to "Off".
2. Check oil level in pump. See
"Oil" paragraph in the
"Maintenance" section for
instructions.
3. Pull regulator knob out, turn
counter-clockwise until it stops.
Push knob in to lock in place.
4. Attach hose and accessories.
NOTE: The hose or accessory
will require a quick connect plug
if the air outlet is equipped with a
quick connect.
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.
minutes. Make sure the drain
valve is open and there is
minimal air pressure build-up in
tank.
7. After 20 minutes, close the drain
valve (clockwise). The air receiver
will fill to "cut-out" pressure and
the motor will stop.
The compressor is now ready for use.
●
●
18- ENG
D23766
MAINTENANCE
Customer Responsibilities
Daily or
after
each
use
Before
each
use
●
●
●
●
Every
8
hours
Every
40
hours
Every
100
hours
Yearly
Every
160
hours
●
●
1
1- more frequent in dusty or humid conditions
Check Safety Valve
Drain Tank
Oil Leaks
Check Oil
Change Oil
Air Filter
NOTE: See "Operation" section for the location of controls.
To ensure efficient operation and longer life of the air compressor unit, a routine
maintenance schedule should be prepared and followed. The following routine
maintenance schedule is geared to a unit in a normal working environment
operating on a daily basis. If necessary, the schedule should be modified to
suit the conditions under which your compressor is used. The modifications will
depend upon the hours of operation and the working environment. Compressor
units in an extremely dirty and/or hostile environment will require a greater
frequency of all maintenance checks.
Unit cycles automatically when power is on. When
performing maintenance, you may be exposed to voltage
sources, compressed air, or moving parts. Personal injuries can occur.
Before performing any maintenance or repair, disconnect power source
from the compressor and bleed off all air pressure.
To Check Safety Valve
If the safety valve
does not work
properly, over-pressurization may
occur, causing air tank rupture or
an explosion.
●
●
Drive Belt -Condition
Motor Pulley/Flywheel alignment
Air compressor pump intake
and exhaust valves
Unusual Noise and/or Vibration
1. Before starting compressor, pull
the ring on the safety valve to
make sure that the safety valve
operates freely. If the valve is
stuck or does not operate
smoothly, it must be replaced
with the same type of valve.
19- ENG
D23766
Oil
Drain tank to
release air pressure
before removing the oil fill cap or
oil drain plug.
Checking
1. Remove the oil
fill plug (A). The
oil level should
be even with the
top of the fill
hole and no
lower than 6
threads from the
top of fill hole.
A
B
To Drain Tank
1. Set the On/Auto/Off lever to
"Off".
2. Pull the regulator knob out and
turn counter clockwise to set the
outlet pressure to zero.
3. Remove the air tool or
accessory.
4. Pull ring on safety valve allowing
air to bleed from the tank until
tank pressure is approximately
20 psi. Release safety valve ring.
5. Drain water from air tank by
opening drain valve (counterclockwise) on bottom of tank.
Water will
condense in the air
tank. If not drained, water will
corrode and weaken the air tank
causing a risk of air tank rupture.
6. After the water has been drained,
close the drain valve (clockwise).
The air compressor can now be
stored.
NOTE: If drain valve is plugged,
release all air pressure. The valve
can then be removed, cleaned, then
reinstalled.
2. If needed, slowly add oil until it
reaches the top of fill hole.
NOTE: Oil is included with some
units. If oil is not included, use an oil
specifically formulated for use in an
air compressor, such as Porter-Cable
PAS1 air compressor oil. Oil may be
found at the store where the air
compressor was purchased.
Changing
1. Remove the oil fill plug (A).
2. Remove the oil drain plug (B) and
drain oil into a suitable container.
3. Replace the oil drain plug (B) and
tighten securely
4. Slowly fill crankcase to the top of
the fill hole. NOTE: Crankcase oil
capacity is approximately 16 fluid
ounces (473.2 ml).
Over filling with oil
will cause
premature compressor failure. Do
not overfill.
5. Replace oil fill plug (A) and
tighten securely.
Air Filter - Inspection and
Replacement
Hot surfaces.
Risk of burn.
Compressor heads are exposed
when filter cover is removed.
Allow compressor to cool prior to
servicing.
Keep the air filter
clean at all times.
Do not operate the air
compressor with the air filter
removed.
A dirty air filter will not allow the
compressor pump to operate at full
capacity. Before using the
compressor pump, check the air
filter to make sure it is clean and in
place.
If it is dirty, replace it with a new
filter.
2. Remove belt guard
3. Place a straightedge against the
outside of the flywheel and the
motor drive pulley.
4. Measure the distance between
the edge of the belt and the
straightedge at points A1 and A2
in figure. The difference between
measurements should be no
more than 1/16".
5. If the difference is greater or less
than 1/16" loosen the set screw
holding the motor drive pulley to
the shaft and adjust the pulley’s
position on the shaft until the A1
and A2 measurements are within
1/16" of each other.
6. Tighten the motor drive pulley
set screw. See Parts manual for
torque specifications.
7. Visually inspect the motor drive
pulley to verify that it is
perpendicular to the drive motor
shaft. Points B1 and B2 of Figure
should appear to be equal. If
they are not, loosen the setscrew
of the motor drive pulley and
equalize B1 and B2, using care
not to disturb the belt alignment
performed in step 2.
8. Retighten the motor drive pulley
setscrew. See Parts manual for
torque specifications.
9. Reinstall belt guard.
On models with rectangular felt filter:
1. Using a pair of needle nose pliers
or a screwdriver pull or pry out
the old filter and carefully clean
the filter area.
2. Push the new air filter in place.
Refer to the "Repair Parts" for
the correct part number.
On models with round removable air
filter cover:
1. Remove the air filter cover.
2. Remove the air filter from filter
cover.
IMPORTANT: Do not operate the
compressor with the air filter
removed.
3. Place new air filter into filter
cover. Refer to the "Repair Parts"
for the correct part number.
4. Replace air filter cover and lock
into place.
20- ENG
D23766
Motor Pulley/Flywheel
Alignment
NOTE: Once the motor pulley has
been moved from its factory set
location, the grooves of the flywheel
and pulley must be aligned to within
1/16" to prevent excessive belt wear.
The air compressor flywheel and
motor pulley must be in-line (in the
same plane) within 1/16" to assure
belt retention within flywheel belt
grooves. To check alignment,
perform the following steps:
1. Unplug air compressor from
power source.
Air Compressor Pump Intake
and Exhaust Valves
Once a year have a Trained Service
Technician check the air compressor
pump intake and exhaust valves.
21- ENG
D23766
4. Using an adjustable wrench,
loosen pressure relief tube nut at
air tank and pressure switch.
Carefully move pressure relief
tube away from check valve.
5. Unscrew the check valve (turn
counterclockwise) using a 7/8"
open end wrench. Note the
orientation for reassembly.
6. Using a screwdriver, carefully
push the valve disc up and
down. NOTE: The valve disc
should move freely up and down
on a spring which holds the valve
disc in the closed position; if not
moving freely the check valve
needs to be cleaned or replaced.
7. Clean or replace the check valve.
A solvent, such as paint or
varnish remover can be used to
clean the check valve.
8. Apply sealant to the check valve
threads. Reinstall the check valve
(turn clockwise).
9. Replace the pressure release
tube. Tighten nuts.
10. Replace the outlet tube and
tighten nuts.
11. Perform the Break-in Procedure.
See "Break-in Procedure" in the
Operation section.
SERVICE AND ADJUSTMENTS
To Replace or Clean Check
Valve
1. Release all air pressure from air
tank. See "To Drain Tank" in the
Maintenance section.
2. Unplug unit.
3. Using an adjustable wrench,
loosen outlet tube nut at air tank
and pump. Carefully move outlet
tube away from check valve.
Outlet Tube
Nuts
Nuts
Pressure
Relief Tube
Check
Valve
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, unplug the
compressor and bleed off all air
pressure.
ALL SERVICE AND REPAIR
OPERATIONS NOT DESCRIBED IN
THIS MANUAL MUST BE
PERFORMED BY A TRAINED
SERVICE TECHNICIAN.
Before servicing:
• Unplug or disconnect electrical
supply to the air compressor.
• Bleed tank of pressure.
• Allow the air compressor to
cool.
In closed position
disc is visible.
In open
position
nothing is
visible.
Screwdriver
22- ENG
D23766
4. Remove the outlet pressure
gauge, tank pressure gauge, and
quick connect (if equipped) from
the regulator.
5. Remove the regulator. NOTE: If
regulator comes in contact with
tank and is unable to be
removed follow these steps:
a. Using an adjustable wrench
loosen pressure relief tube
nut at air tank and pressure
switch.
b. Lift retaining clip from handle
and remove handle.
Motor
This motor has a manual 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. To
restart:
1. Place the On/Auto/Off lever in
the "Off" position.
2. Allow the motor to cool.
3. Depress the red reset button on
the motor.
4. Place the On/Auto/Off lever in
the "On/Auto" position to restart
the motor.
Pressure Switch - Replacement
Pressure loads
beyond design
limits may cause tank rupture or
explosion. Pressure switch
operation is related to motor HP,
tank rating, and safety valve
setting. Do not attempt to adjust,
remove, or defeat the pressure
switch, or change and modify any
pressure control related device. If
replacement is necessary the same
rated switch must be used.
Contact a trained service
technician for replacement.
To Replace Regulator
1. Release all air pressure from air
tank. See "To Drain Tank" in the
Maintenance section.
2. Unplug air compressor.
3. Remove the regulator ring and
remove the console cover.
Regulator
Ring
Cover
Outlet
Pressure
Gauge
Regulator
Tank
Pressure
Gauge
Retaining clip
Handle
Quick
Connect
Reset
Button
23- ENG
D23766
c. Using an adjustable wrench,
rotate the pressure switch
assembly as shown.
d. It is now possible to remove
regulator.
6. Apply pipe sealant tape to the
nipple.
7. Assemble the regulator and
orient as shown in figure.
NOTE: Arrow indicates flow of air.
Make sure it is pointing in the
direction of air flow.
8. Reapply pipe sealant to outlet
pressure gauge, tank pressure
gauge, and quick connect.
9. Reassemble outlet pressure
gauge, tank pressure gauge, and
quick connect. Orient outlet
pressure gauge and tank
pressure gauge to read correctly.
Tighten quick connect with
wrench.
10. If necessary, rotate pressure
switch assembly into correct
position.
11. If necessary, tighten pressure
relief tube nuts at air tank and
pressure switch.
12. If necessary, replace handle.
Refer to Handle Assembly
paragraph in the Assembly
section.
13. Replace console cover and
regulator ring.
To Replace Belt
Serious injury or
damage may occur
if parts of the body or loose items
get caught in moving parts. Never
operate the unit with the belt guard
removed. The belt guard should be
removed only when the
compressor is unplugged.
1. Place the ON/AUTO-OFF lever in
the "OFF" position.
2. Unplug compressor.
3. Remove the front of the belt
guard by disengaging the snaps.
Insert a flat bladed screwdriver at
each snap location and pry the
beltguard apart.
4. Loosen the wing nut on hold
down plate and tilt motor to
allow for easy removal or
installation of the belt.
5. Remove belt.
6. Replace belt. NOTE: The belt
must be centered over the
grooves on the flywheel and
motor pulley.
7. Turn the wing nut on the hold
down plate until it makes contact
with the washer, plus one
additional turn.
8. Replace the belt guard.
Wing Nut
Arrow
Regulator
24- ENG
D23766
STORAGE
Before you store the air compressor,
make sure you do the following:
1. Review the "Maintenance"
section on the preceding pages
and perform scheduled
maintenance as necessary.
2. Set the On/Auto/Off lever to
"Off".
3. Turn the regulator
counterclockwise and set the
outlet pressure to zero.
4. Remove the air tool or accessory.
5. Pull ring on safety valve allowing
air to bleed from the tank until
tank pressure is approximately
20 psi. Release safety valve ring.
6. Drain water from air tank by
opening drain valve on bottom of
tank.
Water will
condense in the air
tank. If not drained, water will
corrode and weaken the air tank
causing a risk of air tank rupture.
7. After the water has been drained,
close the drain or drain valve.
NOTE: If drain valve is plugged,
release all air pressure. The valve
can then be removed, cleaned, then
reinstalled.
8. Protect the electrical cord and air
hose from damage (such as
being stepped on or run over).
Wind them loosely around the
compressor handle. (If so
equipped)
Store the air compressor in a clean
and dry location.
25- ENG
D23766D23766
TROUBLESHOOTING
Performing repairs may expose voltage sources, moving
parts or compressed air sources, moving parts or
compressed air sources. Personal injury may occur. Prior to attempting any
repairs, unplug the air compressor and bleed off all air tank air pressure.
PROBLEM
CAUSE
CORRECTION
Pressure switch does not
shut off motor when
compressor reaches "cutout" pressure.
Pressure switch "cut-out"
too high.
Move On/Auto/Off lever to
the "Off" position, if the unit
does not shut off contact a
Trained Service Technician.
Contact a Trained Service
Technician.
Excessive tank
pressure safety valve
pops off.
Tube fittings are not tight
enough.
Tighten fittings where air can
be heard escaping. Check
fittings with soapy water
solution. DO NOT OVER
TIGHTEN.
Air leaks at
fittings.
Air leaks at
pressure switch
release valve.
Defective pressure switch
release valve.
Contact a Trained Service
Technician.
Air leaks in air
tank or at air
tank welds.
Defective air tank.
Air tank must be replaced.
Do not repair the leak.
Do not drill
into, weld
or otherwise modify air
tank or it will weaken. The
tank can rupture or
explode.
Air leaks
between head
and valve plate.
Leaking seal.
Contact a Trained Service
Technician.
Air leaks at or
inside check
valve.
Check valve seat damaged.
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. Replace check
valve. Refer the "To Replace
or Clean Check Valve" in the
"Operation" section.
26- ENG
D23766D23766
PROBLEM
CAUSE
CORRECTION
Compressor is
not supplying
enough air to
operate
accessories.
Prolonged excessive use of
air.
Compressor is not large
enough for air requirement.
Hole in hose.
Check valve restricted.
Air leaks.
Restricted air intake filter.
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.
Check and replace if required.
Remove and clean, or replace.
Tighten fittings.
Clean or replace air intake
filter. Do not operate the air
compressor with the filter
removed. Refer to the "Air
Filter" paragraph in the
"Maintenance " section.
Pressure reading
on the regulated
pressure gauge
(if equipped)
drops when an
accessory is
used.
It is normal for "some"
pressure drop to occur.
If there is an excessive amount
of pressure drop when the
accessory is used, adjust the
regulator as instructed in the
Operation section.
NOTE: Adjust the regulated
pressure under flow conditions
(while accessory is being
used).
Possible defect in safety
valve.
Operate safety valve manually
by pulling on ring. If valve still
leaks, it should be replaced.
Air leak from
safety valve.
Clean or replace. See Air Filter
paragraph in the Maintenance
section.
Dirty air filter.
Restricted air
intake.
Loose belt.
Loosen wingnut and then
tighten wingnut until it contacts
the washer, plus one turn.
Damaged regulator. Replace.Regulator knob
has continuous
air leak.
Regulator will
not shut off air
outlet.
Damaged regulator. Replace.
27- ENG
D23766D23766
PROBLEM
CAUSE
CORRECTION
Motor will not
run.
Fuse blown, circuit breaker
tripped.
1. Check fuse box for blown
fuse and replace as
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. You
should use a time delay
fuse.
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.
Motor overload protection
switch has tripped.
Let motor cool off and
overload switch will
automatically reset.
Tank pressure exceeds
pressure switch "cut-in"
pressure.
Motor will start automatically
when tank pressure drops
below "cut-in" pressure of
pressure switch.
Loose electrical
connections.
Check wiring connection
inside pressure switch and
terminal box area.
Have checked by a Trained
Service Technician.
Check valve stuck open.
Remove and clean, or replace.
Possible defective motor
or starting capacitor.
Have checked by a Trained
Service Technician. Do not
operate the compressor in the
paint spray area. See
flammable vapor warning.
Paint spray on internal
motor parts.
Bleed the line by pushing the
lever on the pressure switch to
the "Off" position; if the valve
does not open, replace switch.
Pressure release valve on
pressure switch has not
unloaded head pressure.
28- ENG
D23766D23766
PROBLEM
CAUSE
CORRECTION
Knocking Noise.
Possible defect in safety
valve.
Operate safety valve manually
by pulling on ring. If valve still
leaks, it should be replaced.
Loose pulley. Tighten pulley set screw, see
Parts manual for torque
specifications.
Compressor mounting
screws loose.
Tighten mounting screws,see
Parts manual for torque
specifications.
Loose flywheel. Tighten flywheel screw, see
Parts manual for torque
specifications.
Loose belt.
Loosen wingnut and then
tighten wingnut until it
contacts the washer, plus one
turn.
Carbon build-up in pump. Have checked by a Trained
Service Technician.
Belt to tight. Loosen wingnut and then
tighten wingnut until it
contacts the washer, plus one
turn.
Excessive belt
wear.
Loose belt.
Tight belt.
Loose pulley.
Have checked by a Trained
Service Technician.
Pulley misalignment.
See Motor Pulley/Flywheel
Alignment paragraph in the
Maintenance section.
Squealing
sound.
Loose belt.
Compressor pump has no
oil.
See Oil-Checking paragraph in
the Maintenance section.
Loosen wingnut and then
tighten wingnut until it
contacts the washer, plus one
turn.
Loosen wingnut and then
tighten wingnut until it
contacts the washer, plus one
turn.
Loosen wingnut and then
tighten wingnut until it
contacts the washer, plus one
turn.
Defective check valve. Remove and clean, or replace.
Loading...