Excell Precision E7540 User Manual
E7540
Operation Manual • Guide d’utilisation • Manual de operación
IMPORTANT
Please make certain that the person who is to use this equipment carefully
reads and understands these instructions before operating.
Part No. A18791 Rev. 0 06/12/06
SAFETY GUIDELINES - DEFINITIONS
Safety Guidelines/Definitions..................2
Important Safety Instructions ..............2-7
Specifications .......................................... 8
Glossary ................................................... 8
Duty Cycle ...............................................8
Accessories ............................................. 8
Assembly ................................................. 9
Installation ........................................ 10-12
Operaton .......................................... 13-15
Maintenance .................................... 16-19
Service and Adjustments......................20
Storage ..................................................21
Troubleshooting Guide .................... 22-25
Warranty.................................................26
Français ........................................... 27-52
Español ............................................ 53-78
SAFETY GUIDELINES - DEFINITIONS
This manual contains information that is important for you to know and
understand. This information relates to protecting YOUR SAFETY and
PREVENTING EQUIPMENT PROBLEMS. To help you recognize this
information, we use the symbols below. Please read the manual and pay
attention to these symbols.
Indicates an
imminently hazardous
situation which, if not avoided, will result
in death or serious injury.
Indicates a potentially
hazardous situation
which, if not avoided, could result in
death or serious injury.
which, if not avoided, may result in minor
or moderate injury.
indicates a potentially hazardous situation
which, if not avoided, may result in
property damage.
Indicates a potentially
hazardous situation
Used without the
safety alert symbol
IMPORTANT SAFETY INSTRUCTIONS
Some dust created by power sanding, sawing, grinding,
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, al ways
wear MSHA/NIOSH approved, properly fit ting face mask or res pi ra tor when
us ing such tools.
When using air tools, basic safety precautions should always be followed
to reduce the risk of of personal injury.
drilling, and other construction activities contains
2-ENGA18791
IMPORTANT SAFETY INSTRUCTIONS
Save these instructions
Improper operation or maintenance of this product could result in serious injury and
property damage. Read and understand all warnings and operation instructions before
using this equipment.
HAZARD
WARNING: Risk of explosion or fire
What Could Happen
It is normal for electrical contacts
within the motor and pressure switch to
spark.
If electrical sparks from compressor
come into contact with flammable
vapors, they may ignite, causing fire or
explosion.
Restricting any of the compressor
ventilation openings will cause serious
overheating and could cause fire.
Unattended operation of this product
could result in personal injury or
property damage. To reduce the risk
of fire, do not allow the compressor to
operate unattended.
How To Prevent It
Always operate the compressor in a
well ventilated area free of combustible
materials, gasoline, or solvent vapors.
If spraying flammable materials, locate
compressor at least 20 feet away from
spray area. An additional length of hose
may be required.
Store flammable materials in a secure
location away from compressor.
Never place objects against or on top
of compressor. Operate compressor
in an open area at least 12 inches
away from any wall or obstruction that
would restrict the flow of fresh air to the
ventilation openings.
Operate compressor in a clean, dry well
ventilated area. Do not operate unit
indoors or in any confined area.
Always remain in attendance with the
product when it is operating.
Always disconnect electrical power by
moving pressure switch lever to the off
position and drain tank daily or after
each use.
3-ENG A18791
HAZARD
WARNING: Risk of Bursting
Air Tank: The following conditions could lead to a weakening of the tank, and result
in a violent tank explosion and could cause property damage or serious injury.
What Could Happen
Failure to properly drain condensed
water from tank, causing rust and
thinning of the steel tank.
Modifi cations or attempted repairs to
the tank.
Unauthorized modifi cations to the
unloader valve, safety valve, or any
other components which control tank
pressure.
Excessive vibration can weaken the
air tank and cause rupture or
explosion
ATTACHMENTS & ACCESSORIES:
Exceeding the pressure rating of
air tools, spray guns, air operated
accessories, tires, and other inflatables
can cause them to explode or fly apart,
and could result in serious injury.
HAZARD
How To Prevent It
Drain tank daily or after each use. If
tank develops a leak, replace it immediately with a new tank or replace the entire
compressor.
Never drill into, weld, or make any modifications to the tank or its attachments.
The tank is designed to withstand specific
operating pressures. Never make adjust-
ments or parts substitutions to alter the
factory set operating pressures.
For essential control of air pressure, you
must install a pressure regulator and
pressure gauge to the air outlet (if not
equipped) of your compressor. Follow
the equipment manufacturers recommendation and never exceed the maximum
allowable pressure rating of attachments.
Never use compressor to inflate small
low pressure objects such as children’s
toys, footballs, basketballs, etc.
WARNING: Risk from Flying Objects
What Could Happen
The compressed air stream can cause
soft tissue damage to exposed skin
and can propel dirt, chips, loose particles, and small objects at high speed,
resulting in property damage or personal
injury.
How To Prevent It
Always wear ANSI Z87.1 approved safety
glasses with side shields when using the
compressor.
Never point any nozzle or sprayer toward
any part of the body or at other people or
animals.
Always turn the compressor off and
bleed pressure from the air hose and tank
before attempting maintenance, attaching
tools or accessories.
4-ENGA18791
HAZARD
WARNING: Risk of Electrical Shock
What Could Happen
Your air compressor is powered by
electricity. Like any other electrically
powered device, If it is not used
properly it may cause electric shock.
Repairs attempted by unqualified
personnel can result in serious injury
or death by electrocution.
Electrical Grounding: Failure to provide
adequate grounding to this product
could result in serious injury or death
from electrocution.
See grounding instructions.
HAZARD
WARNING: Risk to Breathing
What Could Happen
The compressed air directly from your
compressor is not safe for breathing.
The air stream may contain carbon
monoxide, toxic vapors, or solid
particles from the tank. Breathing these
contaminants can cause serious injury
or death.
How To Prevent It
Never operate the compressor outdoors
when it is raining or in wet conditions.
Never operate compressor with protective covers removed or damaged.
Any electrical wiring or repairs required
on this product should be performed by
authorized service center personnel in
accordance with national and local electrical codes.
Make certain that the electrical circuit
to which the compressor is connected
provides proper electrical grounding,
correct voltage and adequate fuse
protection.
How To Prevent It
Air obtained directly from the compressor
should never be used to supply air for
human consumption. In order to use air
produced by this compressor for breathing,
suitable filters and in-line safety equip-
ment must be properly installed. In-line
filters and safety equipment used in
conjunction with the compressor must be
capable of treating air to all applicable
local and federal codes prior to human
consumption.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides,
weed killers, may contain harmful va-
pors and poisons.
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.
5-ENG A18791
HAZARD
WARNING: Risk of Burns
What Could Happen
Touching exposed metal such as the
compressor head or outlet tubes, can
result in serious burns.
HAZARD
WARNING: Risk from Moving Parts
What Could Happen
Moving parts such as the pulley, flywheel,
and belt can cause serious injury if
they come into contact with you or your
clothing.
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.
HAZARD
WARNING: Risk of Falling
How To Prevent It
Never touch any exposed metal parts
on compressor during or immediately
after operation. Compressor will remain
hot for several minutes after operation.
Do not reach around protective shrouds
or attempt maintenance until unit has
been allowed to cool.
How To Prevent It
Never operate the compressor with
guards or covers which are damaged or
removed.
Any repairs required on this product
should be performed by authorized
service center personnel.
What Could Happen
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.
How To Prevent It
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.
6-ENGA18791
HAZARD
WARNING: Risk of Serious Injury or Property Damage When
Transporting Compressor
(Fire, Inhalation, Damage to Vehicle Surfaces)
What Could Happen
Oil can leak or spill and could result in
fire or breathing hazard; serious injury or
death can result. oil leaks will damage carpet, paint or other surfaces in
vehicles or trailers.
Always place COMPRESSOR on a pro-
tective mat when transporting to protect
against damage to vehicle from leaks.
Remove COMPRESSOR from vehicle immediately upon arrival at your destination.
How To Prevent It
HAZARD
WARNING: Risk of Unsafe Operation
What Could Happen
Unsafe op er a tion of your air compressor
could lead to se ri ous in ju ry or death to
you or others.
SAVE THESE INSTRUCTIONS
How To Prevent It
Review and understand all instructions
and warnings in this manual.
Be come fa mil iar with the op er a tion and
con trols of the air compressor.
Keep operating area clear of all persons,
pets, and obstacles.
Keep chil dren away from the air compres-
sor 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 fea tures of this
prod uct.
Equip area of operation with a fire extinguisher.
Do not op er ate machine with missing,
broken, or un au tho rized parts.
7-ENG A18791
SPECIFICATIONS
Model No. E7540
Running Horsepower 6.0
Voltage-Single Phase 240V
Minimum Branch Circuit Requirement 30 amps
*Fuse Type Time Delay
Air Tank Capacity, Gallons 80 ASME, Vertical
Approximate Cut-in Pressure 140 PSIG
Approximate Cut-out Pressure 175 PSIG
SCFM @ 100 psig 14.0
SCFM @ 175 psig
13.5
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. 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.
To Lock Out Power: Place a lock on the line power switch so no one else can
turn on the power.
DUTY CYCLE
This air compressor pump is capable of running continuously. However, to prolong the life of your air compressor, it is recommended that a 50%-75% average
duty cycle be maintained; that is, the air compressor pump should not run more
than 30-45 minutes in any given hour.
ACCESSORIES
Accessories for this unit are available at the store the unit was purchased.
8-ENGA18791
ASSEMBLY
Contents of Carton
1 - Air Compressor 1 - Operator’s Manual
1 - Parts bag containing: 1 - Parts Manual
1 - Parts Manual 4 - 5/8" Washers
Tools Required for Assembly
1 - 9/16" socket or open end wrench
1 - Electric drill
Unpacking
1. Remove all packaging.
It may be necessary to brace or support one side of the
will have a tendency to tip.
2. Remove and discard the (4) screws and washers holding the compressor to
the pallet.
3. With the help of another person carefully remove air compressor from pallet
and place on a level surface.
To Add Oil To Pump
the correct amount of oil to the pump crankcase. Serious damage can
result from even the minimal operation if the pump crankcase does not
contain the correct amount of oil. Make sure the break-in procedure is
completed before operating the air compressor.
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.
2. Remove oil fill plug (A) and slowly add a
compressor oil to the middle of sight
glass (B). NOTE: 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.
NOTE: Crankcase oil capacity is
approximately 48 fluid ounces.
3. Replace oil fill plug.
outfit when removing the pallet because the air compressor
Compressors are shipped with some oil due to factory
testing. Do not operate this air compressor without adding
Multi-Viscosity motor oils, like 10W30, should not be used
in an air compressor. They leave carbon deposits on critical
Drain tank to release air pressure before removing the oil fill
cap or oil drain plug.
A
B
9-ENG A18791
INSTALLATION
HOW TO SET UP YOUR UNIT
Location of the Air Compressor
• Locate the air compressor in a clean, dry, and well ventilated area.
• Located the air compressor at least 12" away from the wall or other
obstructions that will interfere with the flow of air.
• Locate the air compressor as close to the main power supply as possible
to avoid using long lengths of electrical wiring. NOTE: Long lengths of
electrical wiring could cause power loss to the motor.
• The air filter must be kept clear of obstructions which could reduce air flow
to the air compressor.
Anchoring of the Air Compressor
Risk of Bursting. Excessive Vibration can weaken the air
properly mounted.
The air compressor MUST be bolted to a solid, level surface.
Hardware needed:
4 - Concrete anchors (not supplied)
4 - 3/8" Lag screw to fit concrete anchors
4 - 5/8" Washer (supplied)
shims (if needed)
1. Place the air compressor on a solid, level surface.
2. Mark the surface using the holes in the air compressor feet as a template.
3. Drill holes in the surface for the concrete anchors. Install concrete anchors.
4. Line-up holes in surface with holes in air compressor feet.
5. Place the (4) washers (supplied)
between the floor and air
compressor feet. If needed, solid
shims may be placed between the
washers and floor to evenly
distribute weight on all four feet.
See next figure.
6. Place the (4) 3/8" lag screws
through the air compressor feet,
washers, shims, and into the
anchors.
7. Torque 3/8" lag screws to 7-10 ft.-lbs.
tank and cause an explosion. The compressor must be
(not supplied)
5/8" Washer
(supplied)
Shim Under
Washer
(not supplied)
3/8" Lag
Screw
(not supplied)
Surface Line
Concrete Anchor
(not supplied)
10-ENGA18791
Wiring Instructions
Risk of Electrical Shock. Improper electrical grounding can
result in electrical shock. The wiring should be done by a
qualified electrician
A qualified electrician needs to knows the following before wiring:
1. The amperage rating of the electrical box should be adequate. Refer to the
Specification Chart, in the parts manual, for this information.
2. The supply line should have the same electrical characteristics (voltage,
cycle, phase) as the motor. Refer to the motor nameplate, on side of motor,
for this information.
NOTE: The wiring must be the same as the motor nameplate voltage plus or
minus 10%. Refer to local codes for recommended wire sizes, correct wire size,
and maximum wire run; undersize wire causes high amp draw and overheating
to the motor.
Risk of Electrical Shock. Electrical wiring must be located
away from hot surfaces such as manifold assembly,
compressor outlet tubes, heads, or cylinders.
GROUNDING INSTRUCTIONS
This product should be connected to a metallic, permanent wiring system, of an
equipment-grounding terminal or lead on the product.
Voltage and Circuit Protection
Refer to the specification chart for the voltage and minimum branch circuit
requirements.
11-ENG A18791
Air Distribution System
Risk of Bursting. Plastic or PVC pipe is not designed for use
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.
• 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
with compressed air. Regardless of its indicated pressure
FEEDER LINES SLOPE
WITH 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.
AIR USAGE
LINES
AIR FLOW
DRAIN
LEGS
LUBRICATOR
MOISTURE
SEPARATOR
AND TRAP
DIRT
LEG
REGULATOR
DRAIN
TRAP
TYPICAL COMPRESSED
AIR DISTRIBUTION SYSTEM
12-ENGA18791
DIRT
LEG
FILTER
FLEXIBLE
COUPLING
AIR DISCHARGE
DRAIN COCK
VALVE
VALVE
DRAIN
TRAPS
REGULATOR
COMPRESSOR
LUBRICATOR
AIR
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.
Pressure
On/Auto/Off
Switch
Switch
Tank
Pressure
Gauge
Safety Valve
Globe Valve
Description of Operation
Become familiar with these controls before operating the unit.
On/Auto/Off Lever: Turn this switch "On/Auto" to provide automatic power to
the pressure switch and "Off" to remove power at the end of each use.
Pressure Switch: The pressure switch automatically starts the motor when the
air tank pressure drops below the factory set "cut-in" pressure. It stops the motor when the air tank pressure reaches the factory set "cut-out" pressure.
Safety Valve: If the pressure switch does not shut off the air compressor at its
"cut-out" pressure setting, the safety valve will protect against high pressure by
"popping out" at its factory set pressure (slightly higher than the pressure switch
"cut-out" setting).
Tank Pressure Gauge: The tank pressure gauge indicates the reserve air pressure in the tank.
Globe Valve (sold separately): Opens and closes air discharge valve. Turn knob
counter-clockwise to open and clockwise to close.
Regulator (sold separately, not shown): An air pressure regulator or a separate
air transformer which combines the functions of air regulation and/or moisture
and dirt removal is recommended for most applications.
Cooling System (not shown): This compressor contains an advanced design
cooling system. At the heart of this cooling system is an engineered fan. It is
perfectly normal for this fan to blow air through the vent holes in large amounts.
You know that the cooling system is working when air is being expelled.
Air Compressor Pump (not shown): Compresses air into the air tank. Working
air is not available until the compressor has raised the air tank pressure above
that required at the air outlet.
13-ENG A18791
Drain Valve: The drain valve is located at the base of
the air tank and is used to drain condensation at the end of
each use.
Drain
Valve
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-
Check Valve
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.
Pressure
Release
Valve
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 the unit
reaches "cut-out" pressure.
Motor Overload Protector: 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" postion to
restart the motor.
Air Intake Filter (not shown): This filter is designed to
Reset
Button
clean air coming into the pump. This filter must always be
clean and ventilation openings free from obstructions. See "Maintenance".
How to Use Your Unit
How to Stop:
1. Set the On/Auto/Off lever to "Off".
Before Starting
Break-in Procedure
Risk of Unsafe Operation. Serious damage may result if the
following break-in instructions are not closely followed.
This procedure is required before the air compressor is put into service and
when the check valve or a complete compressor pump has been replaced.
1. Make sure the On/Auto/Off lever is in the "Off" position.
2. Check oil level in pump. See "Oil" paragraph in the Maintenance section for
instructions.
3.
Recheck all wiring. Make sure wires are secure at all terminals connections.
Make sure all contacts move freely and are not obstructed.
4. Open the globe valve fully to permit air to escape and prevent air pressure
build up in the air tank during the break-in period.
5. Move the On/Auto/Off lever to "On/Auto" position. The compressor will start.
14-ENGA18791
6. Run the compressor for 20 minutes. Make sure the globe valve is open and
there is minimal air pressure build-up in tank.
7. Check all air line fittings and connections/piping for air leaks by applying a
soap solution. Correct if necessary. NOTE: Minor leaks can cause the air
compressor to overwork, resulting in premature breakdown or inadequate
performance.
8. Check for excessive vibration. Readjust or shim air compressor feet, if necessary.
9. After 20 minutes, close the globe valve. The air receiver will fill to "cut-out"
pressure and the motor will stop.
Before Each Start-Up:
1. Place On/Auto/Off lever to "Off".
2. Close the globe valve.
3. Attach hose and accessories. NOTE: A regulator MUST be installed when
using accessories rated at less than 175 PSI.
NOTE: The hose or accessory will require a quick connect plug if the air outlet
is equipped with a quick connect socket.
Risk of Bursting. Too much air pressure causes a hazard-
ous risk of bursting. Check the manufacturer’s maximum
pressure rating for air tools and accessories. The regulator outlet pressure
must never exceed.
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. When the tank pressure reaches "cut-out" pressure open the globe valve.
IMPORTANT: When using regulator and other accessories refer to the manufac-
turers instructions.
The compressor is ready for use.
15-ENG A18791
MAINTENANCE
Customer Responsibilities
Before
each
use
Check Safety Valve
Drain Tank
Oil Leaks
Check Oil
Daily
or after
each
use
Every
8
hours
●
●
●
●
Change Oil
Unusual Noise and/or
Vibration
●
Air Filter
Drive Belt-Condition
Motor Pulley/Flywheel alignment
Air compressor pump intake
and exhaust valves
Inspect air lines and fittings
for leaks
●
Head Bolts - Check the torques of the head bolts after the first five hours of operation.
1- more frequent in dusty or humid conditions
Risk of Unsafe Operation. Unit cycles automatically when
power is on. When servicing, you may be exposed to voltage sources, compressed air, or moving parts. Before servicing unit unplug
or disconnect electrical supply to the air compressor, bleed tank of pressure, and allow the air compressor to cool.
To ensure efficient operation and longer life of the air compressor, a routine
maintenance schedule should be prepared and followed. The above routine
maintenance schedule is geared to an air compressor in a normal working
environment operating on a daily basis. If necessary, the schedule should be
modified to suit the conditions under which your air compressor is used. The
modifications will depend upon the hours of operation and the working environment. Compressors in an extremely dirty and/or hostile environment will require
a greater frequency of all maintenance checks.
NOTE: See Operation section for the location of controls.
Every
40
hours
●
Every
100
hours
1
●
●
Every
160
hours
●
Yearly
●
To Check Safety Valve
Risk of Bursting. If the safety valve does not work properly,
over-pressurization may occur, causing air tank rupture or
an explosion.
1. Before starting compressor, pull the ring on the safety valve to make sure
that the safety valve operates freely. If the valve is stuck or does not operate
smoothly, it must be replaced with the same type of valve.
16-ENGA18791
Drain Tank
NOTE: Operation of the air compressor will cause condensation to build up in
the air tank. Always drain tank on a washable surface or in a suitable container
to prevent damaging or staining surfaces.
1. Set the On/Auto/Off lever to "Off".
2. Close the globe valve.
3. Remove the air tool or accessory.
4. Open the globe valve and allow the air to slowly bleed from the air tank until
tank pressure is approximately 20 psi.
5. Close the globe valve.
6. Drain water from air tank by opening drain valve on bottom
of tank.
Risk of Bursting. Water will condense in the
Open Drain
Valve
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 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.
Closed Drain
Valve
Oil
NOTE: 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.
NOTE: Crankcase oil capacity is approximately 48 fluid ounces (1.4 L).
Checking
1. The oil level should be to the middle of the sight glass (C).
2. If needed remove oil fill plug (A) and slowly add oil until it reaches the
middle of the sight glass.
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. Sowly add compressor oil until
the oil level is in the middle of the
sightglass (C). NOTE: 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.
Risk of Unsafe Operation. Overfilling with oil
will cause premature compressor failure. Do not overfill.
5. Replace oil fill plug (A) and tighten securely.
A
C
B
17-ENG A18791
Air Filter - Inspection and Replacement
Hot surfaces. Risk of burn. Compressor heads are exposed
to servicing.
A dirty air filter will not allow the compressor to operate at full capacity. Keep the
air filter clean at all times.
1. Remove air filter.
2. Remove the air filter cover.
3. Remove the air filter from filter cover.
IMPORTANT: Do not operate the compressor with the air filter removed.
4. Place new air filter into filter cover. Refer to the Repair Parts for the correct
part number.
5. Replace air filter cover and reassemble air filter to pump.
when filter cover is removed. Allow compressor to cool prior
Keep the air filter clean at all times. Do not operate the air
compressor with the air filter removed.
Belt - Replacement
(Refer to the Parts Manual for replacement belt part number.)
Serious injury or damage may occur if parts of the body or
outfit with the belt guard removed. The belt guard should be removed only
when the air compressor power is disconnected.
1. Turn air compressor off, lock out the power supply, and relieve all air pres-
sure from the air tank.
2. Remove the belt guard.
3. Mark pump position on saddle.
4. Loosen the motor mounting screws and slide the motor toward the air com-
pressor.
5. Remove the belt and replace with a new one.
6. See the "Adjust Belt Tension" before tightening motor mounting screws.
loose items get caught in moving parts. Never operate the
Adjusting Belt Tension
1. Slide motor into original position, line the motor up with the mark made
earlier on saddle.
2. Tighten two outside motor mounting screws enough to hold the motor in
place for checking pulley and
flywheel alignment.
3. The belt should deflect 3/16" at
midway between the pulley and
the flywheel when a 5-10 pound
weight is applied at the midway
point.
4. When proper belt tension is
achieved, tighten all four motor mounting screws. See Parts
manual for torque specifications.
Downward Force
Deflection
18-ENGA18791
NOTE: Once the engine 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. Verify the alignment by performing the following Pulley and Flywheel - Alignment.
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. Turn air compressor off, lock out the power supply, and relieve all air
pressure from the air tank.
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 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.
Air Compressor Pump Intake and Exhaust Valves
Once a year have a Trained Service Technician check the air compressor pump
intake and exhaust valves.
Inspect Air Lines and Fittings for Leaks
1. Turn air compressor off, lock out the power supply, and relieve all air
pressure from the air tank.
2. Apply a soap solution to all air line fittings and connections/piping.
3. Correct any leaks found.
IMPORTANT: Even minor leaks can cause the air compressor to overwork,
resulting in premature breakdown or inadequate performance.
Air compressor Head Bolts - Torquing
The air compressor pump head bolts should be kept properly torqued. Check
the torques of the head bolts after the first five hours of operation. Retighten if
necessary. See Parts manual for torque specifications
19-ENG A18791
SERVICE AND ADJUSTMENTS
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE
PERFORMED BY TRAINED SERVICE TECHNICIAN.
Risk of Unsafe Operation. Unit cycles automatically when
sources, compressed air, or moving parts. Before servicing unit unplug or
disconnect electrical supply to the air compressor, bleed tank of pressure,
and allow the air compressor to cool.
To Replace or Clean Check Valve
1. Release all air pressure from air tank. See "To Drain Tank" in the
Maintenance section.
2. Turn air compressor off, lock out the power supply, and relieve all air
pressure from the air tank.
3. Using an adjustable wrench loosen outlet tube nut at air tank and pump.
Carefully move outlet tube away from check valve.
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 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.
Additional Service
Disassembly or service of the air compressor beyond what is covered in this
manual is not recommended. If additional service is required, contact your nearest Authorized Warranty
power is on. When servicing, you may be exposed to voltage
Screwdriver
In open
position
nothing is
visible.
In closed position
disc is visible.
20-ENGA18791
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. Close the globe valve.
4. Remove the air tool or accessory.
5. Open the globe valve and allow the air to slowly bleed from the air tank
until tank pressure is approximately 20 psi.
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
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 air hose from damage (such as being stepped on or run over).
corrode and weaken the air tank causing a risk of air tank
21-ENG A18791
TROUBLESHOOTING
Performing repairs may expose voltage sources, moving
Prior to attempting any repairs, unplug the air compressor and bleed off all
air tank air pressure.
parts or compressed air sources. Personal injury may occur.
PROBLEM
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.
CAUSE
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.
Check valve seat damaged.
Defective pressure switch
release valve.
CORRECTION
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.
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. Replace check
valve. Refer the "To Replace
or Clean Check Valve" in the
Service and Adjustments
section.
Contact a Trained Service
Technician.
Air leaks in air
tank or at air
tank welds.
Air leaks between head and
valve plate.
Defective air tank.
Leaking seal.
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.
Contact a Trained Service
Technician.
22-ENGA18791
PROBLEM
Pressure reading
on the regulated
pressure gauge
(if equipped)
drops when an
accessory is
used.
Air leak from
safety valve.
CAUSE
It is normal for "some"
pressure drop to occur.
Possible defect in safety
valve.
CORRECTION
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).
Operate safety valve manually
by pulling on ring. If valve still
leaks, it should be replaced.
Compressor is
not supplying
enough air to
operate accessories.
Restricted air
intake.
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.
Loose belt.
Dirty air 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.
Check belt tension, see Adjusting Belt Tension in the Maintenance section.
Clean or replace. See Air Filter
paragraph in the Maintenance
section.
23-ENG A18791
PROBLEM
Motor will not
run.
CAUSE
Motor overload protection
switch has tripped.
Tank pressure exceeds
pressure switch "cut-in"
pressure.
Check valve stuck open.
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.
Remove and clean, or replace.
Loose electrical
connections.
Possible defective motor
or starting capacitor.
Paint spray on internal
motor parts.
Pressure release valve on
pressure switch has not
unloaded head pressure.
Fuse blown, circuit breaker
tripped.
Check wiring connection
inside pressure switch and
terminal box area.
Have checked by a Trained
Service Technician.
Have checked by a Trained
Service Technician. Do not
operate the compressor in
the paint spray area. See
flammable vapor warning.
Bleed the line by pushing the
lever on the pressure switch to
the "Off" position; if the valve
does not open, replace switch.
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.
Safety Valve
on pump
"pops" out (if
equipped).
Pressure switch, check
valve, or pump could be
in need of servicing.
24-ENGA18791
Have checked by a Trained
Service Technician.
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