Harbor Freight Tools 67853 User Manual

30 Gallon, 180 PSI Gas Powered Two-Stage Air Compressor

67853 Air Compressor

Using an engine indoors CAN KILL YOU IN MINUTES.

Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

If any parts are missing or broken, please call 1-800-444-3353 as soon as possible.

Record Product’s Serial Number Here:

Note: If product has no serial number, record month and year of purchase instead.

Note: Some parts are listed and shown for illustration purposes only, and are not available individually

as replacement parts.

Only use OUTSIDE and far away from windows, doors, and vents.

When unpacking, make sure that the product is intact and undamaged.

Visit our website at: http://www.harborfreight.com

Email our tech support at: tech@harborfreight.com

or form without the express written consent of Harbor Freight Tools. Diagrams within this manual may not be drawn proportionally. Due to continuing

improvements, actual product may differ slightly from the product described herein. Tools required for assembly and service may not be included.

Manual Revised 11e

Save This Manual

Keep this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and the receipt in a safe and dry place for future reference.

Safety Warnings

Symbol Denitions

Symbol Property or Statement

RPM

Revolutions Per Minute

Horsepower

WARNING marking concerning Risk of Eye Injury. Wear ANSI-approved safety goggles with side shields.

In this manual, on the labeling, and all other information provided with this product:

This is the safety alert symbol. It is used

to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

Read the manual before set-up and/or use.

WARNING marking concerning Risk of Hearing Loss. Wear hearing protection.

WARNING marking concerning Risk of Respiratory Injury. Operate engine OUTSIDE and far away from windows, doors, and vents.

WARNING marking concerning Risk of Fire while handling fuel. Do not smoke while handling fuel.

WARNING marking concerning Risk of Fire. Do not refuel while operating.

Keepammableobjectsawayfromengine.

WARNING marking concerning Risk of Explosion.

WARNING! Read all instructions.

Failure to follow all instructions listed below may result in re, serious injury and/or DEATH.

The warnings and precautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

CAUTION, without the safety alert symbol, is used to address practices not related to personal injury.

For technical questions, please call 1-800-444 3353.Item 67853

SAVE THESE INSTRUCTIONS

Set up Precautions

1. Gasolinefuelandfumesareammable,andpotentially explosive. Use proper fuel storage and handling

procedures.Donotstorefuelorotherammable

materials nearby.

2. HavemultipleABCclassreextinguishersnearby.

3. Operation of this equipment may create sparks that

canstartresarounddryvegetation.Asparkarrestor

may be required. The operator should contact local

reagenciesforlawsorregulationsrelatingtore

prevention requirements.

Page 1

4. Setupanduseonlyonaat,level, well-ventilated surface.

5. Use only lubricants and fuel recommended in the

enginemanualorintheSpecicationschartof

this manual.

6. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during set up.

Engine Precautions

Follow engine precautions and instructions in the included engine instruction manual.

Operating Precautions

1. CARBON MONOXIDE HAZARD

Using an engine indoors CAN KILL YOU IN MINUTES.

Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

2. Keep children away from the equipment, especially while it is operating.

3. FireHazard!DonotllgastankwhileCompressor engine is running. Do not operate if gasoline has been spilled. Clean spilled gasoline before starting engine.

Donotoperatenearpilotlightoropename.

4. Do not touch Compressor engine during use. Let engine cool down after use.

5. Neverstorefuelorotherammablematerialsnear the Compressor engine.

6. Only use a suitable means of transport and lifting

deviceswithsufcientweightbearingcapacitywhen

transporting the Compressor.

7. Secure the Compressor on transport vehicles to prevent the tool from rolling, slipping, and tilting.

8. Industrial applications must follow OSHA requirements.

Page 2

For technical questions, please call 1-800-444 3353. Item 67853

9. Do not leave the equipment unattended when it is running. Turn off the equipment (and remove safety keys, if available) before leaving the work area.

10. Wear ANSI-approved safety glasses, hearing protection, and NIOSH-approved dust mask/respirator under a full face shield along with steel-toed work boots during use.

11. People with pacemakers should consult their

physician(s)beforeuse.Electromagneticeldsin

close proximity to a heart pacemaker could cause pacemaker interference or pacemaker failure. Caution is necessary when near the engine’s magneto or recoil starter.

12. Use only accessories that are recommended by Harbor Freight Tools for your model. Accessories that may be suitable for one piece of equipment may become hazardous when used on another piece of equipment.

13. Do not operate in explosive atmospheres, such

asinthepresenceofammableliquids,gases,or

dust. Gasoline-powered engines may ignite the dust or fumes.

14. Stay alert, watch what you are doing and use common sense when operating this piece of equipment. Do not use this piece of equipment while tired or under the

inuenceofdrugs,alcoholormedication.

15. Do not overreach. Keep proper footing and balance at all times. This enables better control of the equipment in unexpected situations.

16. Dress properly. Do not wear loose clothing or jewelry. Keep hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.

17. Parts, especially exhaust system components, get very hot during use. Stay clear of hot parts.

18. Do not cover the engine or equipment during operation.

19. Keep the equipment, engine, and surrounding area clean at all times.

20. Use the equipment, accessories, etc., in accordance with these instructions and in the manner intended for the particular type of equipment, taking into account the working conditions and the work to be performed. Use of the equipment for operations different from those intended could result in a hazardous situation.

21. Do not operate the equipment with known leaks in the engine’s fuel system.

22. This product contains or, when used, produces a chemical known to the State of California to cause cancer and birth defects or other reproductive harm. (California Health & Safety Code § 25249.5, et seq.)

23. When spills of fuel or oil occur, they must be cleaned

upimmediately.Disposeofuidsandcleaning

materials as per any local, state, or federal codes and regulations. Store oil rags in a bottom-ventilated, covered, metal container.

24. Keep hands and feet away from moving parts. Do not reach over or across equipment while operating.

25. Before use, check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the equipment’s operation.

If damaged, have the equipment serviced before using. Many accidents are caused by poorly

maintained equipment.

26. Use the correct equipment for the application. Do not modify the equipment and do not use the equipment for a purpose for which it is not intended.

Service Precautions

1. Before service, maintenance, or cleaning:

a. Turn the engine switch to its “OFF” position.

b. Allow the engine to completely cool.

c. Then, remove the spark plug cap from the

spark plug.

2. Keep all safety guards in place and in proper working

order.Safetyguardsincludemufer,aircleaner,

mechanical guards, and heat shields, among other guards.

3. Do not alter or adjust any part of the equipment

or its engine that is sealed by the manufacturer

or distributor. Only a qualied service technician

may adjust parts that may increase or decrease governed engine speed.

4. Wear ANSI-approved safety goggles, heavy-duty work gloves, and dust mask/respirator during service.

5. Maintain labels and nameplates on the equipment. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

6. Havetheequipmentservicedbyaqualiedrepair person using only identical replacement parts. This will ensure that the safety of the equipment is maintained. Do not attempt any service or maintenance procedures not explained in this manual or any procedures that you are uncertain about your ability to perform safely or correctly.

7. Store equipment out of the reach of children.

8. Follow scheduled engine and equipment maintenance.

Air Compressor Safety Warnings

1. Riskofreorexplosion-Donotsprayammableliquid

inaconnedareaortowardsahotsurface.Sprayarea

must be well-ventilated. Do not smoke while spraying

orspraywheresparkorameispresent.Arcingparts-

Keep compressor at least 20 feet away from explosive vapors, such as when spraying with a spray gun.

2. Risk of bursting - Do not adjust regulator higher than maximum stated pressure of attachment.

3. Risk of injury - Do not direct air stream at people or animals.

4. Do not use to supply breathing air.

5. Do not use the air hose to move the compressor.

6. Drain Tank daily and after use. Internal rust causes tank failure and explosion.

7. Add correct amount of compressor oil before rst

use and every use. Operating with the incorrect amount of oil causes permanent damage and voids warranty. To prevent damage, do not use with

overlled or low oil.

8. Compressor head gets hot during operation. Do not touch it or allow children nearby during or immediately following operation.

9. Release the pressure in the storage tank before moving.

10. The use of accessories or attachments not recommended by the manufacturer may result in a risk of injury to persons.

11. All air line components, including hoses, pipe,

connectors,lters,etc.,mustberatedforaminimum

working pressure of 125 PSI, or 150% of the maximum system pressure, whichever is greater.

SAVE THESE

INSTRUCTIONS.

For technical questions, please call 1-800-444 3353.Item 67853

Page 3

Engine Controls

ON/OFF Switch

Gauge (97)

Belt Guard Frame (121) &

Belt Guard Cover (129)

Tank

Pressure

Air

Outlet

(105)

Pump Safety Valve (91)

Pilot Valve

Air Filter

Assembly (84)

Oil

Sight

Glass

(19)

Tank Safety Valve

(98)

Drain Valve (137)

1. Belt Guard - The Belt Guard encloses the pulleys and drive belts.

It protects the user from the moving parts and allows the large pulley to direct cooling air to the Air Pump.

2. Oil Sight Glass - The oil sight glass shows proper level of the oil.

Oil level should be at center of Sight Glass.

3. Tank Drain Valve - The Air Tank Drain Valve allows moisture to be

removed from the tank to prevent corrosion.

4. Safety Valve - The Safety Valve automatically releases air if the Air

Tank pressure exceeds the preset maximum. In an emergency, the ring can be pulled to relieve tank air pressure. There is one safety valve on the pump and one on the tank.

5. Air Outlet - An air hose attaches to this valve. Air pressure

required by tools is set by an air pressure regulator.

6. Air Storage Tank - The Air Tank is where air pressurized by the Air

Pump is stored for use.

7. Tank Pressure Gauge - The Air Tank Pressure Gauge displays the

air pressure in the tank.

8. Pilot Valve - Open the Pilot Valve before starting the engine. It

relieves resistance on the engine to make starting possible. Rotate the pin so it is vertical to open it. Once the engine is running, close the Pilot Valve so the Compressor can build up pressure.

Oil Sight Glass (19)

Closed

Pilot Valve

Crankcase (16)

OIL LEVEL

OVERFILL

FULL

LOW

Opened

Pilot Valve

REV 11c

Page 4

For technical questions, please call 1-800-444 3353. Item 67853

Set up

The emission control system for this Compressor’s Engine is warranted for standards set by the U.S. Environmental Protection Agency and by the California Air Resources Board (also known as CARB). For warranty information, refer to the engine manual.

Mounting to a Truck bed

1. Before mounting, if needed, reinforce the area with plywood or steel plating.

2. Withassistance,movethecompressortothetruckbedlocationandmarktheoorofthetruckbedthroughtheholes in the compressor’s feet. Check for any hidden wiring or cables and adjust the location for the holes as needed. Then, temporarily set the compressor aside.

3. Drill the four 1/2” diameter holes through the truck bed and any reinforcing materials.

4. Set the compressor back in place, and align the foot holes with the pre-drilled holes. Use four 1/2” diameter, bolts, washers and lock washers (all not included) to secure the compressor in place.

Wing Nut Connector

Air Filter

Assembly (84)

Second Stage Cylinder Head

(21)

First Stage

Cylinder Head

(61)

Assembly

ToinstalltheAirFilterAssembly(84),ttheConnectorintothe

Air Filter Assembly and slide the assembly into the hole on the side of the First Stage Cylinder Head (61). Secure in place with the Wing Nut.

Break-In Compressor

Break in the new Air Compressor as follows:

a. Make sure the engine is off. Open the air outlet valve on the left side of the tank.

b. Checkalluidlevelsintheengineandpump.

c. Start the engine following the General Operating Instructions.

d. Let the unit run for 30 minutes. Air will expel freely through the Coupler.

e. Turn OFF the engine.

f. Remove the male coupler.

Connection

Connect a regulator valve, an in-line shut off valve and a 1/2” NPT air hose (all sold separately) to the Quick Coupler. The air hose must be long enough to reach the work area with enough extra length to allow free movement while working.

Note: An in-line shutoff ball valve is an important safety device because it controls the air supply even if the air hose is ruptured. The shutoff valve should be a ball valve because it can be closed quickly.

1. Depending on the tool which you will be using with this compressor, you may need to incorporate additional

components,suchasanin-lineoiler,alter,oradryer(allsoldseparately).Consultyourairtool’smanualforneeded

accessories. See Typical Air Line Setup charts on the following pages. This is a truckbed compressor, so use the portable setup as a model.

For technical questions, please call 1-800-444 3353.Item 67853

Page 5

Air Tool & Spray Gun Portable Setup

E H

Lubricated

Tools

Non-lubricated

Tools

Description Function

Page 6

A Air Hose Connects air to tool

B Filter Prevents dirt and condensation from damaging tool or work piece

C Regulator Adjusts air pressure to tool

For technical questions, please call 1-800-444 3353. Item 67853

F Leader Hose (optional) Increases coupler life

E Coupler and Plug Provides quick connection and release

D Lubricator (optional) For air tool lubrication

H Air Adjusting Valve (optional) Fornetuningairowattool

G Air Cleaner / Dryer (optional) Prevents water vapor from damaging work piece

Air Tool & Spray Gun Stationary Setup

M N

Slope

Lubricated

Tools

Non-lubricated

Tools

Increases coupler life

Description Function

I Air Cleaner / Dryer (optional) Prevents water vapor from damaging work piece

J Regulator Adjusts air pressure to tool

A Vibration Pads For noise and vibration reduction

B Anchor Bolts Secures air compressor in place

C Ball Valve Isolates sections of system for maintenance

B B

A A

For technical questions, please call 1-800-444 3353.Item 67853

F Ball Valve To drain moisture from system

E Main Air Line - 3/4” minimum recommended Distributes air to branch lines

D Isolation Hose For vibration reduction

H Filter Prevents dirt and condensation from damaging tool or work piece

G Branch Air Line -1/2” minimum recommended Brings air to point of use

L Air Hose Connects air to tool

K Lubricator For air tool lubrication

N Air Adjusting Valve Fornetuningairowattool

O Leader Hose

M Coupler and Plug Provides quick connection and release

Page 7

Operation

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including

all text under subheadings therein before set up or use of this product.

Using the Compressor

Inspect Compressor, engine, pump and equipment looking for damaged, loose, and missing parts before set up and

starting.Ifanyproblemsarefound,donotuseequipmentuntilxedproperly.

Note:Atthebeginningoftheday’srstuseoftheAirCompressor,checkforairleaksbyapplyingsoapywaterto

connections while the Air Compressor is pumping and after pressure cut-out. Look for air bubbles. If air bubbles are present at connections, tighten connections. Do not use the air compressor unless all connections are air tight. The extra air leaking out will cause the compressor to operate too often, increasing wear on the compressor.

Before starting the Compressor:

a. Follow the Set Up Instructions in the equipment manual to prepare the equipment. b. Follow the Set Up Instructions in the Engine manual to prepare the engine. c. Inspect all components of the setup. Make sure all nuts and bolts are tight. d. Fill the Engine with the proper amount and type of both fuel and oil. e. Fill the Compressor Pump with compressor oil following the Maintenance Instructions in

this manual.

To Start and Use the Compressor

1. Close the Drain Valve (137) by turning the lever up so that it is perpendicular to the valve.

2. Close the in-line Shutoff Valve between the compressor and the air hose.

3. Open the Pilot Valve by rotating it to a vertical position.

4. Open the Fuel Valve.

Page 8

For technical questions, please call 1-800-444 3353. Item 67853

5. To start a cold engine, move the Choke to the CHOKE (start/ closed) position. To restart a warm engine, leave the Choke in the RUN position.

6. For MANUAL START A. Turn the Engine Switch to ON.

OFF START

B. Grip the Starter Handle of the Engine loosely and pull it

slowlyseveraltimestoallowthegasolinetoowintothe

Engine’s carburetor. Then pull the Starter Handle gently until resistance is felt. Allow Cable to retract fully and then pull it quickly. Repeat until the engine starts. Note: Do not let the Starter Handle snap back against the engine. Hold it as it recoils so it doesn't hit the engine.

For ELECTRIC START

Turn the Engine Switch to START.

Note: To prolong starter life, use short starting cycles (5 seconds maximum). Then wait one minute before attempting to start again.

OFF START

START

7. Allow the Engine to run for several seconds. Then, if the Choke lever is in the CHOKE position, move the Choke Lever very slowly to its RUN position.

Note: Moving the Choke Lever too fast could kill the engine.

8. Close the Pilot Valve by rotating it to a horizontal position.

For technical questions, please call 1-800-444 3353.Item 67853

Page 9

9. When the Gas Engine is started and running, the compressor Pump starts compressing air into the Air Tank. Open the in-line Shutoff Valve and adjust the Pressure Regulator (sold separately) so that the air output is enough to properly power the tool, but the output will not exceed the tool’s maximum air pressure at any time. Turn the knob clockwise to increase the pressure and counterclockwise to decrease pressure. Adjust the pressure gradually, while checking the air output gauge to set the pressure.

IMPORTANT:Allowtheenginetorunforveminuteswithnoloadaftereachstart-upsothattheenginecanstabilize.

Maintenance Break-in Period:

Breaking-in the engine will help to ensure proper equipment and engine operation. The maintenance break-in period will last about 20 hours of use. After this period, change the engine oil.

Under normal operating conditions, subsequent maintenance follows the schedule explained in the MAINTENANCE AND SERVICING section.

Note: When maximum tank pressure is reached, the compressor automatically disengages, and the engine RPM drops down to idle speed. The engine remains at idle until Air Tank pressure falls to a preset level. The Gas Engine will then accelerate and air pressure once again begins to build up in the Air Tank.

Note: As long as the engine is running, the operation of the Air Compressor is automatic, controlled by an internal pressure switch.

IMPORTANT: The internal pressure switch is not user adjustable; do not make changes to the air pressure settings of the internal pressure switch. Any change to the automatic pressure levels may cause excess pressure to accumulate,

causing a hazardous situation.

Note: Depressurization - If it is necessary to quickly depressurize the Compressor, turn OFF the engine. Then, pull on the ring on the tank Safety Valve to release stored air pressure.

10. Use the air tool as needed.

11. After the job is complete, turn OFF the engine. To stop the engine in an emergency, turn the Engine Switch off.

Under normal conditions, use the following procedure:

a. Turn the Engine Switch off.

b. Close the Fuel Valve.

Page 10

For technical questions, please call 1-800-444 3353. Item 67853

OFF START

OFF

12. Close the in-line Shutoff Valve.

13. Bleed air from the tool then disconnect the tool.

14. Open the Drain Valve at the bottom of the Tank, to release any built-up moisture and the internal tank pressure.

15. Clean, then store the Air Compressor indoors.

For technical questions, please call 1-800-444 3353.Item 67853

Page 11

Maintenance

WARNING

TO PREVENT SERIOUS INJURY FROM ACCIDENTAL STARTING: Turn the Power Switch of the equipment to its “OFF” position, release tank air pressure, wait for the engine to cool, and disconnect the spark plug cap before performing any inspection, maintenance, or cleaning procedures.

TO PREVENT SERIOUS INJURY FROM EQUIPMENT FAILURE: Do not use damaged equipment. If abnormal noise, vibration, or excess smoking occurs, have the problem corrected before further use.

Follow all service instructions in this manual. The engine may fail critically if not serviced properly.

Maintenance Procedures

Many maintenance procedures, including any not detailed in this manual, will need to be

performed by a qualied technician for safety.

If you have any doubts about your ability to safely service the equipment or engine, have

a qualied technician service the equipment

instead.

Adding Oil

Crankcase (16)

Oil Sight Glass (19)

The oil level should be at the center of the “full” level on the Oil Sight Glass, as shown above. Add oil as needed to maintain this level. Do not let the oil level go below the center dot (LOW as shown above) and

donotoverlltheoilsothatitisabovethecenterdot

(OVERFILL as shown above) on the Oil Sight Glass.

2. To add oil:

a. Remove the Oil Plug (17).

b. Using a funnel to avoid spills, pour enough oil into

the pump Crankcase to reach the “full” level in the Oil Sight Glass.

c. Replace the Oil Plug.

OIL LEVEL

OVERFILL

FULL

LOW

Compressor Pump Oil Maintenance

Check oil periodically for clarity. Replace oil if it appears milky or if debris is present, or every 6 months, or

100hoursofruntime,whichevercomesrst.Inharsh

environments such as high heat or high humidity, you will need to replace the oil more frequently.

Change the compressor oil after the rst hour of

use to remove any debris.

Cold Weather Operation

Premium quality 30-weight, non-detergent air compressor oil (sold separately) is recommended for use with this compressor. Start compressor in heated area if outdoor temperatures drop below 32° F. If this is not practical, drain out the old pump oil and use SAE 10W Non-detergent Air Compressor Oil in the pump crankcase instead whenever the compressor’s temperature will fall below 40°. Do not use multiviscosity oil (such as 10W-30), they leave carbon deposits on pump components and lead to accelerated failure. Heavy operation may require heavier viscosity oil.

3. If uncertain which oil to use for this compressor, please call Harbor Freight Tools customer service at 1-800-444-3353 for assistance.

WARNING! To prevent serious injury from burns: Do not add or change the oil while the compressor is in operation. Allow the compressor to cool before replacing oil.

Page 12

For technical questions, please call 1-800-444 3353. Item 67853

Maintenance

Changing Oil

To drain the oil from the Pump Crankcase:

a. Place a container under the Drain Plug.

b. RemovetheOilPlugtoallowairowintothePump.

c. Remove the Drain Plug, allowing the oil to drain into

the container.

d. When the oil is completely drained from the Pump,

replace the Drain Plug.

e. Fill the Pump with new compressor oil to the FULL

level on the Oil Sight Glass.

f. Replace and tighten the Oil Plug.

g. Discard the old oil according to local, state and

federal regulations.

Draining Moisture from the Tank

The Drain Valve is located under the Tank. It must be accessed daily to release all trapped air and moisture from the Tank. This will eliminate condensation which can cause tank corrosion.

To empty the air and condensation:

a. Make sure the compressor engine is off.

b. Place a collection pan under the Drain Valve.

c. Open the Drain Valve by pivoting the lever on the

bottom of the Compressor so the lever is in line with the Drain Valve.

d. When all the pressure is released, close the

Drain Valve by pivoting the lever on the bottom of the compressor so that the lever is perpendicular to the Drain Valve.

Air Filter Maintenance

Check the Air Filter weekly to see if it needs replacement. If working in dirty environments, you may

needtoreplacetheltermoreoften.Toreplacethe

Air Filter:

a. Unthread the Wing Nut holding the Air Filter

Assembly in place.

b. Remove the Air Filter Assembly.

c. Replace with a new Air Filter.

d. Secure in place with the Wing Nut.

Adjusting Belt Tension

1. Remove the Belt Guard Cover (129) and set it aside.

Deection

Distance

Press on the center of the longest span on each

beltwithmoderatengerpressure(4-4.5lb.).Then measurethedeectiondistance,thedistancethatthe beltmoved.Thebeltshoulddeectanywherefrom

1/2” to 1”.

Engine Base

Threaded Rod

(118)

Nut (115)

If either belt deects too much, tighten belts by loosening the four Bolts (110) on the Bottom Plate (114) and moving the engine away from the other pulley slightly by turning the Nut (115) holding the Threaded Rod (118). Secure engine mounting bolts and retest tension. If either belt is too long to be properly tensioned, both belts must be replaced.

4. If either belt deects too little, loosen belts by loosening the Bolts on the Bottom Plate and moving the engine towards the other pulley slightly by turning the Nut (115) on the Threaded Rod (118). Secure engine mounting bolts and retest tension.

5. Before use, replace belt cover.

Engine

Mounting

Bolts

Bolts (110)

Bottom Plate (114)

For technical questions, please call 1-800-444 3353.Item 67853

Page 13

Troubleshooting

Problem Possible Causes Likely Solutions

Engine will not start

(Note: See engine manual for engine

specicissues.)

Compressor overheats

Severe air leakage

Unit stalls

Excessive noise

Oil in the discharge air

Low discharge pressure

COMPRESSOR SPECIFIC:

1. Pilot Valve closed.

2. Tank already pressurized.

1. Incorrect lubrication or not enough lubrication.

2. Worn parts.

1. Poor air outlet seal.

2. Loose cylinder/cylinder head.

3. Damaged valve or housing.

4. Dirty, worn or damaged valve.

1. Low engine idle.

2. Severelycloggedairlter.

3. Improper lubrication.

4. Defective pilot/unloader valve.

1. Loosedrivepulleyorywheel.

2. Misaligned pulleys.

3. Lack of oil in crankcase.

4. Worn connecting rod.

5. Worn wrist pin bushing.

6. Worn bearings.

7. Loose belts.

1. Wrong type of oil or lowquality oil.

2. Overheating.

3. Restricted intake air.

4. Worn piston rings.

5. Excessive moisture in the tank.

1. Air leaks.

2. Leaking valves.

3. Restricted air intake.

4. Blown gaskets.

5. Slipping belts.

COMPRESSOR SPECIFIC:

1. Open pilot valve before start procedure, close after unit is running.

2. Turn engine on. Compressor will turn on as needed when pressure reaches preset level.

1. Lubricate using recommended oil or grease according to directions.

2. Havequaliedtechnicianinspectinternalmechanismand replace parts as needed.

1. Tighten or re-attach using thread seal tape.

2. Tighten cylinder/cylinder head assembly. If cylinder/cylinder head cannot tighten properly, internal parts may be misaligned.

3. Replace damaged components.

4. Clean or replace valve assembly.

1. Qualiedtechnicianshouldincreaseidleto2,200±100RPMby adjusting pressure switch.

2. Replaceairlter.

3. Check for proper oil level.

4. Replace pilot valve.

1. Loose pulleys are a common cause of “knocking”. Tighten appropriate bolts.

2. Align pulleys with straightedge and secure in place.

3. Check for proper oil level.

4. Replace connecting rod.

5. Remove piston assembly and replace necessary parts.

6. Replace bearings and oil.

7. Check for proper belt tension.

1. Change oil. Check oil recommendations under EQUIPMENT SET UP, Equipment Oil Fill section of this manual.

2. See above Excessive Noise section.

3. Cleanorreplaceairlter.

4. Replace piston rings.

5. Drain moisture from the tank daily.

1. Listenforescapingair.Applysoapsolutiontoallttingsand connections. Bubbles will appear at points of leakage. Tighten

orreplaceleakingttingsorconnections.

2. Remove head and inspect for valve breakage, weak valves, scored valve plate, etc. Replace defective parts and reassemble. Replace head gasket each time the head is removed.

3. Cleanorreplaceairlterelement.

4. Replace and gaskets proven faulty on inspection.

5. Tighten Belts (See monthly maintenance.)

Page 14

Follow all safety precautions whenever diagnosing or servicing the equipment or engine.

For technical questions, please call 1-800-444 3353. Item 67853

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