Husky TF291204 Use And Care Manual

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Page 1

USE AND CARE GUIDE

80-GALLON STATIONARY AIR COMPRESSOR

Questions, problems, missing parts? Before returning to the store, call

Item # 1000 772 228

Model # TF291204

Husky Customer Service 8 a.m. - 6 p.m., EST, Monday - Friday

1-888-43-HUSKY

HUSKYTOOLS.COM

We appreciate the trust and conﬁ dence you have placed in Husky through the purchase of this air compressor. We strive to continually create

quality products designed to enhance your home. Visit us online to see our full line of products available for your home improvement needs.

THANK YOU

Thank you for choosing Husky!

Page 2

Table of Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Work Area Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Spraying Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Hardware Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Compressor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Speciﬁ cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation - Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Care and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Safety Information

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

DANGER: Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

IMPORTANT: Indicates important information, that if not followed, may cause damage to equipment.

NOTE: Information that requires special attention.

CALIFORNIA PROPOSITION 65

WARNING: This product or its power cord may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

WARNING: You can create dust when you cut, sand, drill, or grind materials such as wood, paint, metal, concrete, cement, or other masonry. This dust often contains chemicals known to cause cancer, birth defects, or other reproductive harm. Wear protective gear.

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Safety Information (continued)

GENERAL SAFETY

DANGER: Breathable Air Warning: This compressor/pump is NOT equipped and should NOT be used “as is” to supply breathing quality air. For any application of air for human consumption, you must ﬁ t the air compressor/pump with suitable in-line safety and alarm equipment. This additional equipment is necessary to properly ﬁ lter and purify the air to meet minimal speciﬁ cations for Grade D breathing as described in Compressed Gas Association Commodity Speciﬁ cation G 7.1, OSHA 29 CFR 1910. 134, and/or Canadian Standards Associations (CSA).

Disclaimer of Warranties: In the event the compressor is used for the purpose of breathing air application and proper in-line safety and alarm equipment is not simultaneously used, existing warranties are void, and the Manufacturer disclaims any liability whatsoever for any loss, personal injury, or damage.

DANGER: Never attempt to repair or modify a tank! Welding, drilling, or any other modiﬁ cation will weaken the tank, resulting in damage from rupture or explosion. Always replace worn, cracked, or damaged tanks.

CAUTION: See the compressor speciﬁ cation decal for maximum operating pressure. Do not operate with pressure switch or pilot valves set higher than the maximum operating pressure.

IMPORTANT: Drain liquid from the tank daily.

NOTE: The DANGER, WARNING, CAUTION, IMPORTANT, and

NOTE notifications and instructions in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that caution is a factor which cannot be built into this product, but must be supplied by the operator.

1. Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment.

2. Only persons well acquainted with these rules of safe operation should be allowed to use the compressor.

3. Tanks rust from moisture build-up, which weakens the tank. Make sure to drain the tank regularly and inspect periodically for unsafe conditions, such as rust formation and corrosion.

4. Fast moving air will stir up dust and debris which may be harmful. Release air slowly when draining moisture or depressurizing the compressor system.

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Page 4

Safety Information (continued)

WORK AREA SAFETY

WARNING: Motors, electrical equipment, and controls can cause electrical arcs that will ignite a ﬂ ammable gas or vapor. Never operate or repair in or near a ﬂ ammable gas or vapor. Never store ﬂ ammable liquids or gases in the vicinity of the compressor.

WARNING: An ASME code safety relief valve with a setting no higher than the maximum allowable working pressure (MAWP) MUST be installed in the tank for this compressor. The ASME safety valve must have sufﬁ cient ﬂ ow and pressure ratings to protect the pressurized components from bursting.

WARNING: Never use plastic (PVC) pipe for compressed air. Serious injury or death could result.

WARNING: This compressor is extremely top heavy. The unit must be bolted to the ﬂ oor with isolation pads before operating to prevent equipment damage, injury, or death.

WARNING: Do not modify this compressor. Do not use or create accessories not recommended for use with this compressor. Alterations and / or modiﬁ cations are a form of misuse, which could result in a hazardous condition leading to possible personal injury or equipment damage.

CAUTION: Do not use this compressor in an environment where the air is contaminated or dusty. Using this compressor in such an environment may cause equipment damage.

1. Keep visitors away from the compressor, and NEVER allow children in the work area.

2. Before each use, inspect the compressed air system and electrical components for signs of damage, deterioration, weakness, or leakage. Repair or replace defective items before using.

3. Check all fasteners at frequent intervals for proper tightness.

4. If the equipment should start to vibrate abnormally, STOP the engine/motor and check immediately for the cause. Vibration is generally a warning of trouble.

5. To reduce ﬁ re hazard, keep the engine/motor exterior free of oil, solvent, or excessive grease.

6. Never attempt to adjust the ASME safety valve. Keep the safety valve free from paint and other accumulations.

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Safety Information (continued)

PERSONAL SAFETY

WARNING: Never operate the compressor without a beltguard. This unit can start automatically without warning. Personal injury or property damage could occur from contact with moving parts.

CAUTION: Compressor parts may be hot even if the unit is stopped.

1. Wear safety glasses and use hearing protection when operating the unit.

2. Do not stand on or use the unit as a handhold.

3. Do not wear loose clothing or jewelry that will get caught in the moving parts of the unit.

4. Keep ﬁ ngers away from a running compressor; fast moving and hot parts will cause injury and/or burns. Compressor parts may be hot even if the unit is stopped.

ELECTRICAL SAFETY

WARNING: Improper electrical grounding can result in electrical shock. The wiring should be done by a qualiﬁ ed electrician.

CAUTION: Improper electrical installation of this product may void its warranty. Have circuit wiring performed by qualiﬁ ed personnel, such as a licensed electrician who is familiar with the current national and local electrical codes.

1. Follow all local electrical and safety codes as well as in the United States, the National Electrical Codes (NEC), and Occupational Safety and Health Act (OSHA).

2. Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators. There is an increased risk of electric shock if your body is grounded.

3. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock.

4. Replace damaged cords / wiring immediately. Damaged cords / wiring increase the risk of electric shock.

SPRAYING PRECAUTIONS

WARNING: Do not spray ﬂ ammable materials in the vicinity of open ﬂ ame or near ignition sources including the compressor unit.

1. Do not smoke when spraying paint, insecticides, or other ﬂ ammable substances.

2. Use a face mask / respirator when spraying and spray in a well ventilated area to prevent health and ﬁ re hazards.

3. Do not direct paint or other sprayed material at the compressor. Locate the compressor as far away from the spraying area as possible to minimize overspray accumulation on the compressor.

4. When spraying or cleaning with solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer.

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Page 6

Warranty

LIMITED TWO-YEAR WARRANTY

WHAT IS COVERED

From the date of purchase, parts and labor are covered to remedy substantial defects due to material and workmanship during the ﬁ rst year of ownership with the exceptions noted below. From the date of purchase, parts only are covered to remedy substantial defects due to material and workmanship during the second year of coverage with exceptions noted below.

This warranty applies only to the original retail purchaser and may not be transferred. If the compressor is used for commercial, industrial, or rental purposes, the warranty will apply for ninety (90) days from the date of purchase. Two-stage compressors are not limited to a ninety (90) day warranty when used in commercial or industrial applications. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.

WARRANTOR: Campbell Hausfeld / Scott Fetzer Company, 100 Production Drive, Harrison, Ohio, 45030 Telephone: (800) 543-6400

The responsibilities of the warrantor under this warranty is to repair or replace, at the warrantor’s option, this compressor or components which are defective, have malfunctioned, and/or have failed to conform within the duration of the specific warranty period. Repair or replacement will be scheduled and serviced according to the normal work-flow at the servicing location and will depend on the availability of replacement parts.

The responsibilities of the purchaser under this warranty are as follows: a) provide dated proof of purchase and maintenance records; b) call to obtain your warranty service options [freight costs must be borne by the purchaser]; c) use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s); d) repairs requiring overtime, weekend rates, or anything beyond the standard manufacturer warranty repair labor reimbursement rate; e) time required for any security checks, safety training, or similar for service personnel to gain access to facility; and f) location of unit must have adequate clearance for service personnel to perform repairs and easily accessible.

WHAT IS NOT COVERED

This warranty does not cover normal wear and tear or any malfunction, failure, or defect resulting from misuse, abuse, neglect, alteration, modiﬁ cation, or repair by other than a service center authorized by the manufacturer to repair this air compressor. Expendable materials, such as motor brushes, seals, etc. are not covered by this warranty. This warranty does not apply to this compressor used in industrial applications or for rental purposes. Husky makes no warranties, representations, or promises as to the quality or performance of its air compressors other than those speciﬁ cally stated in this warranty.

Implied warranties, including those of merchantability and ﬁ tness for a particular purpose, are limited to two years from the date of original purchase by the consumer. Any incidental, indirect, or consequential loss, damage, or expense that may result from any defect, failure, or malfunction of the

manufacturer’s product is not covered by this warranty. Some states do not allow the exclusion or limitations of incidental or consequential damages, so the above limitation or exclusion may not apply to you. The warranty does not cover any failure that results from an accident, purchaser’s abuse, neglect, or failure to operate products in accordance with instructions provided in the owner’s manual(s) supplied with compressor.

This warranty does not cover pre-delivery service, i.e. assembly, oil or lubricants, and adjustment. This warranty does not cover items or service that is normally required to maintain the product, i.e. lubricants, ﬁ lters, gaskets, etc.

Gasoline engines and components are expressly excluded from coverage under this limited warranty. The purchaser must comply with the warranty given by the engine manufacturer which is supplied with the product.

The following items not covered under this warranty. This warranty excludes these items (pertaining to all compressors) as follows: a) any component damaged in shipment or any failure caused by installing or operating unit under conditions not in accordance with installation and operation guidelines or damaged by contact with tools or surroundings; b) pump or valve failure caused by rain, excessive humidity, corrosive environments, or other contaminants; c) cosmetic defects that do not interfere with compressor functionality; d) rusted tanks, including but not limited to rust due to improper drainage or corrosive environments; e) any components that are considered normal wear items and are not covered after the ﬁ rst year of ownership [the electric motor, check valve, pressure switch, regulator, pressure gauges, hose, tubing, pipe, ﬁ ttings and couplers, screws, nuts, hardware items, belts, pulleys, ﬂ ywheel, air ﬁ lter and housing, gaskets, seals, oil leaks, air leaks, oil consumption or usage, piston rings]; f) the tank drain valves; g) damage due to incorrect voltage or improper wiring; h) other items not listed but considered general wear parts; i) pressure switches, air governors, load/unload devices, throttle control devices, and safety valves modiﬁ ed from factory settings; j) damage from inadequate ﬁ lter maintenance; and k) induction motors operated with electricity produced by a generator.

The following items not covered under this warranty. This warranty excludes these items (speciﬁ c to lubricated compressors) as follows: a) pump wear or valve damage caused by using oil not speciﬁ ed; b) pump wear or damage caused by any oil contamination; and c) pump wear or damage caused by failure to follow proper oil maintenance guidelines, operation below proper oil level, or operation without oil.

Labor, service calls, or transportation charges after the ﬁ rst year of ownership are not covered on stationary air compressors. Stationary air compressors are deﬁ ned as those units not including a handle or wheels.

This Limited Warranty applies in the U.S., Canada, and Mexico only This warranty gives you speciﬁ c legal rights, and you may also have other rights which vary from state to state.

How to get service: Call 1-888-43-HUSKY or visit www.HUSKYTOOLS.com.

Page 7

Pre-Installation

PLANNING INSTALLATION

WARNING: Disconnect, tag, and lock out the power source before attempting to install or relocate the compressor.

TOOLS REQUIRED

Claw hammer Safety goggles

Measuring tape

Hammer drill and masonry bit

HARDWARE INCLUDED

NOTE: Hardware not shown to actual size.

Phillips screwdriver

Adjustable wrenches (2)

Voltage meter Work gloves

Ratchet and 1/2 in. socket

Flat blade screwdriver

Pipe wrench

AA BB CC DD

Part Description Quantity

AA Vibration isolation set (3 metal plates and 6 rubber pads) 3 sets

BB Reducer 1

CC Nipple 1

DD Shut-off valve 1

HARDWARE REQUIRED

NOTE: Hardware not shown to actual size.

Concrete wedge anchors

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Strain relief Thread sealant

tape

Page 8

Pre-Installation

PACKAGE CONTENTS

Part Description Quantity

A Air Compressor Unit 1

B Air Filter Assembly 1

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Pre-Installation

COMPRESSOR COMPONENTS

GJH K

Side View

Part Description

A Pressure Switch - The compressor shuts off automatically when the tank pressure reaches the maximum preset pressure.

After air is used from the tank and drops to a preset low level, the pressure switch signals the magnetic starter to turn the motor back on. When the motor turns off, you will hear air leaking out of the pressure switch unloader valve for a short time.

This releases the air pressure from the discharge tube and allows the compressor to restart easier.

B ASME Safety Valve - This valve automatically releases air if the tank pressure exceeds the preset maximum.

C Discharge Tube - This tube carries compressed air from the pump to the check valve. This tube becomes very hot during use.

To avoid the risk of severe burns, never touch the discharge tube.

D Check Valve (not visible) - One-way valve that allows air to enter the tank, but prevents air in the tank from flowing back into

the compressor pump.

E Belt Guard - Covers the belt, motor pulley, and flywheel.

F Drain Valve - Use this valve to drain moisture from the tank daily to reduce the risk of corrosion.

G Tank Pressure Gauge - Indicates the amount of air pr

H Outlet Pressure Gauge - Indicates the amount of air pressure being delivered out the discharge port.

I Air Filter - Keeps large particulates out of the air flowing into the compressor.

J Regulator - Controls the amount of air pressure released at the discharge port.

K Universal Coupler - A dir

L Discharge Port - Air delivery port for transfer of compressed air.

M Magnetic Starter - Controls the start and stop of the motor based on the signal from the pressure switch.

ect connect to the air compressor unit for use of air hose(s).

essure stored in the tank.

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Page 10

Pre-Installation (continued)

SPECIFICATIONS

Horsepower (HP)

Number of Cylinders

Voltage

Air Delivery @ 175 psi

Air Delivery @ 90 psi

Max. Air Pressure

7.5

230 / 240 Volts, 31 Amps

60 Hz,

1 Phase

22.2 SCFM

23.7 SCFM

175 psi

Tank Outlet Size

Oil Capacity

Length

Width

Height

Weight

3/4 NPT

approximately 2 quarts

29 in.

33 in.

77 in.

540 lbs.

Page 11

Installation - Mounting

Preparing for installation

WARNING: Disconnect, tag, and lock out the power source, and then release all pressure from the system before attempting to install, service, relocate, or perform any maintenance.

WARNING: This compressor is extremely top heavy. Enlist additional help to remove it from the shipping skid.

CAUTION: Never use the shipping skid for mounting the compressor.

IMPORTANT: Provide a minimum clearance of 18 in. between the compressor ﬂ ywheel or fan and the wall, and ensure clear access to the drain valve to facilitate condensate drainage.

IMPORTANT: It is extremely important to install the compressor in a clean, well ventilated area where the surrounding air temperature will not be more than 100°F.

IMPORTANT: Do not locate the compressor air inlet near steam, paint spray, sandblast areas, or any other source of contamination.

IMPORTANT: This compressor is not intended for outdoor installation.

□ Unbolt the air compressor unit (A) from the shipping skid.

Use a ratchet with a 1/2 in. socket.

□ Remove the air compressor unit (A) from the skid. This

requires at least two people - one person to “walk” the unit off the skid and one to help maintain balance so the unit does not topple. Place the air compressor unit (A) where you plan to install it (at least 18 in. from any wall or surface).

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Page 12

Installation - Mounting (continued)

Drilling the mounting holes

WARNING: This compressor is extremely top heavy. The unit must be bolted to the ﬂ oor with isolation pads before operating to prevent equipment damage, injury, or death.

□ Place the pre-drilled vibration pads (AA) under each air

compressor unit (A) foot to avoid unnecessary vibration which could damage the air compressor unit (A).

□ Using the mounting holes and the holes of the vibration

pads (AA) as a guide, drill holes into the concrete using a 3/8 in. masonry bit. Holes drilled must be at least as deep as the concrete wedge anchors being used.

Inserting the mounting bolts

□ Insert the mounting bolts into the drilled holes.

□ Place a washer on each bolt. Thread a nut onto each bolt

until the top of the nuts and bolts are ﬂ ush.

□ Strike the bolt heads with a hammer until the nuts and

washers are sitting on top of the air compressor unit (A) foot.

Setting the mounting bolts

□ Tighten the nuts using a ratchet with a 9/16 in. socket until

the anchors are set.

□ Use the installation torque speciﬁ cations of the bolt

(provided by the bolt manufacturer).

□ Loosen the nuts to leave a 1/16 in. (1.6 mm) gap for stress

relief during the air compressor unit (A) operation.

Page 13

Installation - Electrical

Preparing for installation

DANGER: Improperly grounded motors are shock

hazards. Make sure all the equipment is properly grounded.

WARNING: All wiring and electrical connections must be performed by a qualiﬁ ed electrician familiar with industrial motor controls. Installations must be in accordance with local and national codes.

WARNING: Disconnect, tag, and lock out the power source, and then release all pressure from the system before attempting to install, service, relocate, or perform any maintenance.

WARNING: Overheating, short circuiting, and ﬁ re damage will result from inadequate wiring.

IMPORTANT: Damage to the motor from improper electrical voltage or connection will void the warranty.

This product must be grounded. If the unit comes with a factory installed cord, plug the cord into a properly sized, grounded outlet. For units that do not have a factory installed cord, install permanent wiring from the electrical source to the pressure switch with a ground conductor connected to the grounding screw on the pressure switch. A properly sized cord with a ground conductor and plug may also be installed by the user.

Local electrical wiring codes differ from area to area. Source wiring and protector must be rated for at least the amperage and voltage indicated on the motor nameplate, and meet all electrical codes for this minimum. The minimum wire size should also meet all electrical codes, and wiring used up to 75 ft. long must be 10 AWG. Use a slow blow fuse type T or a 240-Volt double-pole circuit breaker (1).

□ Conﬁ rm the voltage of the incoming mains (2,3) using a

voltage meter (4).

□ The voltage meter should read 230 / 240 Volts. Do not

proceed with installation if the voltage meter gives a different reading.

□ Conﬁ rm the voltage of the incoming mains (5) and ground

wire (6) using a voltage meter (7).

□ The voltage meter should read 120 Volts. Do not proceed

with installation if the voltage meter gives a different reading.

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Page 14

Installation - Electrical (continued)

Preparing the magnetic starter

□ Remove the magnetic starter cover by loosening the

screw (1), as shown. Use a Phillips screwdriver.

□ Lift the cover upwards from the bottom and off the base.

□ Set the cover aside until wiring is completed.

□ Familiarize yourself with these internal components of the

magnetic starter.

□ Refer to the illustration below to identify the

ground wire (2) from pressure switch, ground screw (3), wires from pressure switch (4), wires from motor (5), thermal overload (6), and terminal screws (7).

Page 15

Installation - Electrical (continued)

Making the electrical connections

□ Use a blunt tool and hammer to carefully tap out the

stamped cover (1) at the top of the magnetic starter box (2).

□ Loosen the ground screw (3). Loosen the terminal

screws (4).

□ Install the strain relief (5) on the magnetic starter (2). Do

not tighten the screws (6) or nut (7) of the strain relief (5) on the power cord until wiring is complete.

□ Insert the bare wires [black, red, bare/green](8, 9, 10)

through the strain relief (5).

□ Attach the bare/green ground wire (10) ﬁ rst to the ground

screw (3) on the magnetic starter body.

□ Install the line wires (8, 9) and tighten the terminal

screws (4).

5 6

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Page 16

Installation - Electrical (continued)

Securing the strain relief

□ Tighten the strain relief nut (1). Place a ﬂ athead

screwdriver into the raised notch, and tap the screwdriver with a hammer until tight.

□ Tighten the strain relief screws (2) to hold the power cord

securely.

Reinstalling the magnetic starter

cover

□ Replace the magnetic starter cover.

□ Tighten the magnetic cover screw (1) with a Phillips

screwdriver. Follow the break-in procedure from the owner’s manual.

Page 17

Assembly

Assembling the air compressor unit

WARNING: Never use plastic (PVC) pipe for compressed

air. Serious injury or death could result.

WARNING: Never install a shut-off valve between the

compressor pump and the tank. Personal injury and / or equipment damage may occur. Never use reducers in discharge piping.

NOTE: Do not overtighten. Over the life of the unit, you will clean or replace the ﬁ lter as needed.

This air compressor unit can be installed as part of an air distribution system. Any tube, pipe, or hose used in an air distribution system must have a pressure rating higher than 175 psi. The minimum recommended pipe size is 3/4 in. Using a larger diameter pipe is always better.

Use thread sealant tape on all the threadded connections of the air compressor unit (A). This will prevent any air leaks between the assembled parts.

□ Screw the air ﬁ lter (B) onto the pump air intake.

□ Install the proviced reducer (BB) into the discharge port of

the tank.

□ Attach the nipple (CC) to the reducer (BB).

□ Connect the shut-off valve (DD) to the nipple (CC).

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Page 18

Operation

Preparing for use

CAUTION: Check for proper oil level before operating!

NOTE: The pump oil level is full (1) as shown.

NOTE: Use SAE 30 industrial grade air compressor oil or

full synthetic motor oil like Mobil 1® 10W30.

NOTE: Do not exceed the maximum oil capacity of approximately 2 qts.

NOTE: Do not use regular automotive oil. Additives in regular motor oil can cause valve deposits and reduce pump life.

NOTE: For maximum pump life, drain and replace oil after the ﬁ rst hour of run time.

□ Use the sight glass on the pump to determine the oil level.

□ Add oil to the pump if the oil level is low (2).

Starting-up and breaking-in the

compressor

WARNING: Do not attach air tools to the open end of the

hose until start-up is completed and the unit checks okay.

WARNING: Never disconnect threaded joints with

pressure in the tank!

□ Open the tank drain valve. The tank will not readily buildup

any pressure.

□ Return power to the air compressor unit (A) from the main.

□ Run the air compressor unit (A) for thirty (30) minutes at

zero (0) psi (under no load) to break-in the pump parts.

□ Turn power off to the air compressor unit (A) from the

main. Close the tank drain valve to shut off air flow. The air compressor unit (A) is now ready for use.

Page 19

Operation (continued)

ON/OFF CYCLING OF THE COMPRESSOR

The air compressor unit (A) is designed to cycle on and off. When the shut-off (preset “cut-out”) pressure is reached, the compressor automatically shuts off.

When air is depleted from the tank by use of a tire chuck, tool, etc., the compressor will restart automatically at its preset “cut-in” pressure. When a tool is in use, the compressor will cycle on and off automatically as needed to maintain air pressure in the tank.

MAGNETIC STARTER

CAUTION: Repeated overloads can cause damage to the motor and void the product warranty.

The magnetic starter is a large relay that switches high current from the main power line in response to a signal from the pressure switch. The starter also has a device to protect the electric motor against overheating due to overcurrent. This protection is accomplished by heater elements that become hot in response to the motor current. The heaters are sized so that overcurrent causes them to interrupt power to the section of the starter controlling motor current, turning the motor off. After the heater elements cool, reset the starter to resume operation.

In normal operation, the starter requires no attention. If an overload occurs, follow the thermal overload reset instructions in the Maintenance section of this manual.

MOISTURE IN COMPRESSED AIR

WARNING: Drain the tank every day to prevent corrosion

and possible injury due to tank damage. For optimal performance of the tank drain, the tank pressure should be between 10 - 50 psi. Do not operate the drain with more than 40 psi in the tank or the drain valve may be damaged. Drain the tank of moisture daily using the drain valve in the side of the tank or at the bottom of the tank.

IMPORTANT: This condensation will cause water spots in a paint job, especially when spraying other than water based paints. If sandblasting, it will cause the sand to cake and clog the gun, rendering it ineffective. A ﬁ lter in the air line, located as near to the gun as possible, will help eliminate this moisture.

IMPORTANT: Drain liquid from the tank daily.

Moisture in compressed air will form into droplets as it comes from an air compressor pump. When humidity is high or when a compressor is in continuous use for an extended period of time, this moisture will collect in the tank. When using a paint spray or sandblast gun, this water will be carried from the tank through the hose, and out of the gun as droplets mixed with the spray material.

Follow the tank draining instructions in the Maintenance section of this manual.

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Page 20

Maintenance

GENERAL MAINTENACE

All repairs should be performed by an authorized service representative.

WARNING: Disconnect, tag, and lock out the power source, and then release all pressure from the system before attempting to install, service, relocate, or perform any maintenance.

Checking and changing the oil

Maintain the proper oil level by checking the oil sight glass (1) daily. Change the oil in the pump every 3 months. Use the following procedure to change (or add) oil.

□ Run the compressor for ten minutes to warm up the oil if the

unit has not been in use for an extended period of time.

□ Turn the compressor off and disconnect the compressor

from the power source.

□ Position a pan under the pump drain plug (2) to catch the oil.

□ Remove the pump drain plug (2) and allow the oil to collect

in the pan.

□ Reinsert the oil drain plug. Remove the oil ﬁ ll plug (3). Pour

new, unused oil into the pump. Do not overﬁ ll.

□ Reinsert the oil ﬁ ll plug (3) into position. Return power to the

compressor for use.

Checking the ASME safety valve

□ Run the air compressor until it reaches cut-out pressure.

□ Turn the compressor off and disconnect the compressor

from the power source.

□ Put on safety glasses. Protect yourself from fast moving air.

□ Pull on the ring of the ASME safety valve (1). This

releases pressure from the tank. The safety valve should automatically close at approximately 40 - 50 psi.

If the safety valve does not allow air to be released when you pull on the ring, or if it does not close automatically, it MUST be replaced.

Draining the tank of moisture

□ Turn the compressor off and disconnect it from the power

source.

□ Release the pressure from the compressor by pulling on

the ASME safety valve. The ASME safety valve should close at approximately 40 - 50 psi.

□ Open the drain valve (1) underneath the tank. Remaining

air pressure will assist in removing moisture from the tank.

Page 21

Maintenance (continued)

Checking the belt

□ Remove the four caps (1) and four ﬂ ange nuts (2).

□ Remove the front beltguard (3).

□ Pull the front beltguard (3) away from the air compressor

unit (A).

□ If the belt appears to be in working order and has no signs

of damage, return the front beltguard (3) to the original position.

□ Tighten the ﬂ ange nuts (2) and reinstall the caps (1).

□ If the belt needs to be replaced, move on to the next step.

Removing the belt

□ Loosen (but do not remove) the four bolts (1) holding the

motor in place.

□ Shift the motor towards the pump. The belt should be slack

and easily removed.

□ Replace the belt.

□ Move the motor back to the original position to create belt

tension.

□ Tighten the motor bolts.

Aligning / tensioning the belt

□ Lay a straightedge (1) against the face of the ﬂ ywheel

touching the rim at two places (2,3).

□ Adjust the flywheel or motor pulley so that the belt (4) runs

parallel to the straightedge. Use a gear puller to move the pulley on the motor shaft. Tighten the setscrew after the pulley is positioned.

□ Adjust the motor’s distance from the pump if needed.

□ Belt tension is determined by how much the belt moves

when weight is applied. The belt should move no more than 3/8 to 1/2 in. downward if normal thumb pressure is placed on it.

□ Tighten the motor bolts once the proper belt tension is

achieved.

□ Reattach the belt guard.

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Page 22

Maintenance (continued)

Reseting the thermal overload

Allow the air compressor unit (A) to cool down after thermal overload of the magnetic starter is tripped.

□ Disconnect, tag, and lock out the power source for the air

compressor unit (A).

□ Push the external reset switch (1). The internal overload

switch (2) will be pushed back into place and return contact for the electrical current.

□ Return power to the air compressor unit (A).

If the air compressor unit (A) does not return to normal operation, other maintenance may be required.

□ Disconnect, tag, and lock out the power source for the air

compressor unit (A).

□ Remove the magnetic starter cover by loosening the

screw (3), as shown. Use a Phillips screwdriver.

□ Lift the cover upwards from the bottom and off the base.

Set the cover aside.

□ Remove the internal overload switch (2) and replace.

Contact Husky Customer Service at 1-888-43-HUSKY for assistance.

THERMAL OVERLOAD CAUSES

In normal operation, the starter requires no attention. If an overload occurs, the compressor motor will not restart, even when the tank pressure drops. It is important to find the cause of the overload and correct it. Overloads can be caused by one of the following:

1. Pressure setting too high: Check to make sure the pressure switch opens at or before the maximum rated operating pressure of the air compressor unit. If the pressure switch fails to operate correctly, contact Husky Customer Service at 1-888-43-HUSKY for assistance.

2. Low voltage condition: Voltage at the motor terminals must be within 10% of the rated voltage during start-up and while the motor is running. Have a qualified electrician check this and correct it as needed.

3. Loose connections or open fuse: Loose connections or blown fuses cause high currents in the remaining wires of the circuit. Have a qualified electrician check and correct these conditions.

4. Unloader valve or check valve malfunction: The motor will overload if it starts against the air trapped in the discharge tube. Replace valves that are not working correctly. Contact Husky Customer Service at 1-888-43-HUSKY for assistance.

Page 23

Maintenance (continued)

Checking the air ﬁ lter

□ Remove the nut (1).

□ Remove the air ﬁ lter cover (2) from the air ﬁ lter base (4).

□ Remove and inspect the air ﬁ lter element (3).

□ If the air ﬁ lter element is dirty, replace it. Install a new ﬁ lter

element. If the air ﬁ lter element is clean, reinstall it.

□ Reattach the air ﬁ lter cover (2).

□ Reattach the nut (1). Do not overtighten the nut as this

maintenance process will be repeated regularly. The nut (1) should be snug enough to hold the air ﬁ lter cover (2) in place.

13 24

MAINTENANCE SCHEDULE

WARNING: Disconnect, tag, and lock out the power source, and then release all pressure from the system before attempting to install, service, relocate, or perform any maintenance.

Operation Daily Weekly Monthly Every 3 Months

Check Oil Level X Drain Tank X Check Air Filter X Check Safety Valve X Clean Unit X Check Belt Tension X Change Oil X

IMPORTANT: Change oil after the ﬁ rst ﬁ fty (50) hours of operation. Then perform oil changes every three (3) months.

Care and Cleaning

WARNING: Disconnect, tag, and lock out the power

source, and then release all pressure from the system before attempting to install, service, relocate, or perform any maintenance.

□ Keep all surfaces clear of debris and dirt.

□ Do not attempt to clean the unit while running. Turn off the unit, disconnect it from the mains, and allow the unit to cool down.

□ Check the air ﬁ lter weekly to see if it needs to be cleaned. Remove the ﬁ lter element. Use hot, soapy water to clean the ﬁ lter and allow

the ﬁ lter to dry before reinstalling and returning the unit to active duty. Replace a ﬁ lter that cannot be cleaned.

23 HUSKYTOOLS.COM

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Page 24

Troubleshooting

Problem Possible Cause Solution

The discharge pressure is low.

The pump is overheating and causing the air ﬁ lter to melt.

The air compressor unit is making excessive noise (a knocking sound).

There is a large quantity of oil in the discharge air.

NOTE: In an oil lubricated compressor there will always be a small amount of oil in the air stream.

There is water in discharge air / tank.

The pressure switch does not release air when the unit shuts off.

□ The air demand exceeds the pump

capacity.

□ The air intake is restricted. □ Clean or replace the air ﬁ lter element.

□ There are air leaks in the ﬁ ttings,

tubing on the compressor, or the plumbing outside the unit.

□ There are blown gaskets. □ Replace any gaskets proven faulty on inspection.

□ There are leaking or damaged

valves.

□ The insulating gasket between the

ﬁ lter and the head is missing.

□ There are broken valves / blown

gaskets.

□ The motor pulley or the ﬂ ywheel is

loose.

□ The fasteners on the pump or the

motor are loose.

□ There is no oil in the crankcase. □ Check for proper oil level; if the oil level is low, check for possible

□ The connecting rod is worn. □ Replace the connecting rod. Maintain the oil level and change the

□ The piston pin bores are worn. □ Remove the piston assemblies from the compressor and inspect

□ The piston is hitting the valve plate. □ Remove the compressor head and the valve plate and inspect for

□ There is a noisy check valve in the

compressor system.

□ The piston rings are worn. □ Replace with new rings. Maintain the oil level and change the oil

□ The compressor’s air intake is

restricted.

□ There is excessive oil in the

compressor.

□ The oil viscosity is wrong. □ Only use Mobil 1

□ This is normal during operation.

The amount of water increases with humid weather.

□ The unloader valve on the pressure

switch is malfunctioning.

□ Reduce the air demand or use a compressor with more capacity.

□ Listen for escaping air. Apply soap solution to all ﬁ ttings and

connections. Bubbles will appear at points of leakage. Tighten or replace leaking ﬁ ttings or connections. Use pipe thread sealant.

□ Remove the head and inspect for valve breakage, misaligned

valves, damaged valve seats, etc. Replace defective parts and reassemble. Install a new head gasket each time the head is removed.

□ Install the gasket.

□ Replace the valves or install the new gasket.

□ Tighten the pulley / ﬂ ywheel clamp bolts and the set-screws.

□ Tighten the fasteners.

damage to the bearings. Dirty oil can cause excessive wear.

oil more frequently.

for excess wear. Replace the excessively worn piston pin or pistons, as required. Maintain the oil level and change the oil more frequently.

carbon deposits or other foreign matter on the top of the piston. Replace the head and the valve plate using the new gasket. See the Lubrication section for the recommended oil type.

□ Replace the check valve. Do not disassemble the check valve with

air pressure in the tank.

more frequently.

□ Clean or replace the ﬁ lter. Check for other restrictions in the

intake system.

□ Drain oil down to the correct full level.

□ Drain the tank more often. At least daily.

□ Add a ﬁ lter to reduce the amount of water in the air line.

□ Replace the unloader valve if it does not release the pressure

for a short period of time when the unit shuts off. Do not disassemble the check valve with air pressure in the tank.

10W-30.

Page 25

Troubleshooting (continued)

Problem Possible Cause Solution

The motor hums and runs slowly, or the motor does not run at all.

The reset mechanism cuts out repeatedly or the circuit breaker trips repeatedly.

The tank does not hold pressure when the compressor is off and the shut off valve is closed.

The pressure switch continuously blows air out of the unloader valve.

There is excessive vibration.

□ The voltage is low. □ Check incoming voltage. It should be approximately 240 volts.

The motor will not run properly on 208 volts. Low voltage could be due to wires (from electrical source to compressor) being too small in diameter and / or too long. Have a qualiﬁ ed electrician check these conditions and make repairs as needed.

□ There are too many devices on the

same circuit.

□ The electrical connections are loose. □ Check all the electrical connections.

□ The pressure switch is

malfunctioning - the contacts will not close.

□ The check valve is malfunctioning. □ Replace the check valve. Do not disassemble the check valve with

□ The unloader valve on the pressure

switch is defective.

□ The motor capacitor(s) are defective. □ Replace the capacitor(s).

□ The motor is defective. □ Replace the motor.

□ There is not proper ventilation for

the air compressor unit, or the room temperature too high.

□ There are too many devices on the

same circuit.

□ The air intake is restricted. □ Clean or replace the air ﬁ lter element.

□ The electrical connections are loose. □ Check all the electrical connections.

□ The pressure switch shut-off

pressure is set too high.

□ The check valve is malfunctioning. □ Replace the check valve. Do not disassemble the check valve with

□ The unloader valve on the pressure

switch is defective.

□ The motor capacitor(s) are defective. □ Replace the capacitor(s).

□ The motor is defective

□ There are air leaks in the ﬁ ttings,

tubing on the compressor, or the plumbing outside the unit.

□ The check valve is worn. □ Replace the check valve. Do not disassemble the check valve with

□ Check the tank for cracks or pin

holes.

□ The check valve is malfunctioning. □ Replace the check valve if the unloader valve on the pressure

□ The fasteners on the pump or the

motor are loose.

□ The belt needs to be replaced. □ Replace the belt. Make sure to use the correct size.

□ The belt needs to be aligned. □ Align the ﬂ ywheel and the pulley.

. □ Replace the motor.

□ Limit the circuit to the use of the compressor only.

□ Replace the pressure switch.

air pressure in the tank.

□ Replace the unloader valve.

□ Move the compressor to a well-ventilated area.

□ Limit the circuit to the use of only the air compressor.

□ Replace the pressure switch.

air pressure in the tank.

□ Replace the unloader valve.

□ Listen for escaping air. Apply soap solution to all ﬁ ttings and

connections. Bubbles will appear at points of leakage. Tighten or replace leaking ﬁ ttings or connections. Use pipe thread sealant.

air pressure in the tank.

□ Replace the tank. Never try to repair a damaged tank.

switch bleeds off constantly when the unit shuts off. Do not disassemble the check valve with air pressure in the tank.

□ Tighten the fasteners.

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Page 26

Troubleshooting (continued)

Problem Possible Cause Solution

The motor hums and runs

wly or not at all.

slo

The oil in the oil reservoir of the pump is milky.

There is excessive oil consumption or oil in the air lines of the air compressor unit (A).

The air compressor

unit (A) builds up pressure quickly.

Interstage safety valve pops off when the unit is running.

□ The voltage supplied to the air

compressor unit is low or not present.

□ The motor winding is shorted or

open.

□ The check valve or the unloader valve

is malfunctioning.

□ The pressure switch is

malfunctioning and the contacts will not close.

□ Water is condensing in the

crankcase due to high humidity.

□ The air intake is restricted. □ Clean or replace the air filter.

□ The oil in the pump is the wrong type

or viscosity.

□ The piston rings are worn. □ Replace the piston rings.

□ Oil leaks out of the pump. □ Tighten the bolts, replace the gaskets or replace the o-rings of the

□ The cylinde is scored or damaged. □ Replace the cylinder of the pump.

□ There is excessive water in the tank. □ Drain the tank.

□ Valve problem or worn gasket. □ Check and replace valve or gaskets.

□ Low head bolt torque. □ Check and retighten head bolts to specified torque.

□ Defective interstage safety valve. □ Replace interstage safety valve. Under no circumstances plug the

□ Check the incoming voltage with a voltmeter. Check the overload

relay in magnetic starter or the reset switch on the motor. If the overload or the reset switch trips repeatedly, find and correct the cause.

□ Replace the motor.

□ Replace the check valve or the unloader valve.

□ Repair or replace the pressure switch.

□ Pipe the air intake to a less humid air source. Then run the air

compressor unit (A) continuously under no load for one hour. Open the drain valve to prevent the air compressor unit from building pressure.

□ Drain the air compressor unit (A) of oil. Refill with new oil of the

proper viscosity.

pump.

safety valve port.

Page 27

Notes

___________________________________________________________________________________________________________

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Page 28

Service Parts - Compressor

MODEL TF291204

Page 29

Service Parts - Compressor (continued)

Part Description Part Number Qty

1 Hex head cap screw,

7/16 - 14 x 1-1/2 ST070645AV 4

2 Hex head cap screw,

3/8 - 16 x 1-1/4 ST070638AV 4

3 Washer, 7/16 ST070916AV 8

4 Washer, 3/8 ST070914AV 4

5 Washer, 5/16 ST011200AV 4

6 Flange nut, 3/8 - 16 ST033500AV 4

7 Hex nut, 7/16 - 14 -- 4

8 Magnetic starter ST122010AJ 1

9 Pressure switch CW218000AV 1

10 Flywheel washer

11 Self tapping screw,

5/16 - 12 x 3/4 ST016500AV 8

12 Belt BT010601AV 1

13 Button torx screw,

1/4 - 20 x 1/2 ST071626AV 2

14 Tube fitting ST081301AV 1

15 Hex flange nut, 10 - 24 ST116201AV 1

16 Hex head screw,

1/2 - 13 UNC x 1-1/4 ◆ 1

17 Lock washer

18 Side drain assembly D-140501AV 1

19 Hex tapping screw,

5/16 - 12 x 3/4 ST073221AV 6

20 Pump XP7101 1

21 Square key KE001310AV 1

22 Square key -- 1

23 Tank AR210300CG 1

24 Motor MC025100AV 1

25 Check valve CV003404AV 1

26 Exhaust tube XP080000AP 1

27 Compression fitting ST072024AJ 1

28 Magnetic starter bracket BG215300AV 1

29 Drain valve D-1403 1

30 Thermal overload switch PS005554AV 1

31 Pulley PU009799AV 1

32 Flywheel with key FP070041AV 1

33 Manifold assembly WL021100AV 1

34 Push fitting ST119305AV 2

35 Compression nut ST072321AV 1

TX034600AV, ◆

◆

Part Description Part Number Qty

36 Plug ST187200AV 1

37 External tooth lock washer ST072608AV 4

38 5/16 Flange head bolt ST187300AV 1

39 Push connect ST119704AV 2

40 Tube, pressure switch to tank WL005900AV 1

41 Tube, pressure switch to

control panel

42 Unloader tube ST117802AV 1

43 Shut off valve assembly PA117000AV 1

44 Beltguard, back BG221200AV 1

45 Beltguard bracket XP050700AV 1

46 Beltguard, front BG221100AV 1

47 Self tapping screw, 1/4 - 20 ST074415AV 1

48 Screw cap ST075400AV 4

49 Set screw -- 1

50 Safety valve, 200 psi ASME V-215200AV 1

51 Unloader valve (pressure

switch, not shown) CW210001AV 1

-- Not available

REPLACEMENT PARTS KITS

◆

Flywheel bolt kit FP070040AV

WL021410AV 1

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Page 30

Service Parts - Pump

MODEL XP7101

36 35

14 16

Page 31

✖

✤

✖

■ ●

✖

✤

■

▲

Service Parts - Pump (continued)

■

●

◆

▼ ✖

▼

▼ ✖

✖

✤

▲

■

●

◆

▼

✖

✤

Part Description Part Number Qty

1 Oil seal FP070042AV

◆

2 Ball bearing

3 Cooler bracket -- 1

4 Washer

5 Bracket ﬁ xing bolt

6 Crankcase -- 1

7 Fill plug

8 Fill plug o-ring

9 Drain plug -- 1

10 Oil level gauge o-ring

11 Oil level gauge

12 Key

13 Crankshaft

14 High pressure connecting rod

assembly FP070047AV 1

15 Wrist pin retainer

16 Low pressure connecting rod

assembly

17 Bafﬂ e

18 Bearing cap packing

19 Bearing cap

20 Brass washer, M10

21 Breather tube assembly FP070075AV 1

22 Intercooler ﬁ tting without

tapped hole FP070053AV 1

23 Breather assembly FP070070AV 1

24 Cylinder head FP070054AV 1

25 Head bolts, M10 - 1.5 x 100

26 Air ﬁ lter housing with ﬁ lter

element DP500056AV 1

27 Intercooler ﬁ tting with tapped

hole FP070058AV 1

28 1/8 in. NPT Safety valve,

72.5 psi V-208900AV 1

29 Low pressure piston

30 Low pressure oil control ring

31 Low pressure compression

ring

●

✖

▼

■

●

FP070048AV 1

✤

Part Description Part Number Qty

32 Low pressure piston pin

33 High pressure piston pin

34 High pressure piston

35 High pressure oil control ring

36 High pressure compression

ring

37 Cylinder head packing

38 Valve assembly

39 Valve-cylinder packing

40 Cylinder FP070065AV 1

41 Intercooler assembly with

ﬂ are nuts FP070066AV 1

42 Beltguard bracket FP070059AV 1

43 Cylinder-crankcase packing

44 Nut, M10

45 Cylinder stud, M10 x 40

46 Air ﬁ lter element (D5 type)

[not shown] HS050071AV 1

47 Air ﬁ lter element (X5 type)

[not shown] ST073903AV 1

REPLACEMENT PARTS KITS

●

Crankshaft assembly with bearings FP070043AV

▼

Oil level gauge with o-ring DP400045AV

✖

Oil cap with o-ring FP070046AV

✤

Bearing cap with bafﬂ e FP070050AV

Piston ring kit (low pressure) FP070060AV

Piston set (low pressure) FP070061AV

Piston set (high pressure) FP070062AV

Piston ring kit (high pressure) FP070063AV

Valve plate kit FP070064AV

Gasket, oil seal, and o-ring kit (except valve plate to plate gasket) FP070068AV

Assembly fastener set FP070069AV

-- Not available

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Page 32

Questions, problems, missing parts? Before returning to the store,

call Husky Customer Service

8 a.m.-6 p.m., EST, Monday-Friday

1-888-43-HUSKY

HUSKYTOOLS.COM

Retain this manual for future use.

Document Number IN564900AV 7/13

Husky TF291204 Use And Care Manual

Specifications and Main Features

Frequently Asked Questions

User Manual