Jet PT-VW530, JCP-803, JCP-804 Operating Informations

EN

Two Stage Air Compressor

Operating Instructions and Parts Manual

JET

427 New Sanford Road
La Vergne, Tennessee 37086
Ph: 1.800.274.6848
www.jettools.com

Model: JCP-801

Part No. M-506801

Edition 1 03/2016

Copyright © 2016 JET

IN572100AV 3/16

Please read and save these instructions. Read carefully before attempting to
assemble, install, operate or maintain the product described.

Protect yourself and others by observing all safety information. Failure to comply
with instructions could result in personal injury and/or property damage! Retain
instructions for future reference.

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to
this manual or file it for safekeeping.

For parts, product & service information

visit www.jettools.com

Model #: _______________________
Serial #: ________________________
Purchase Date: _________________

REGISTER YOUR PRODUCT ONLINE NOW!

http://www.jettools.com/us/en/service-and-support/warranty/registration/

READ AND FOLLOW ALL INSTRUCTIONS • SAVE THESE INSTRUCTIONS • DO NOT DISCARD

427 New Sanford Road

La Vergne, TN 37086

Phone: [phone]

JET

BEFORE YOU BEGIN

Introduction

The JET two-stage air compressors are oil lubricated reciprocating compressors.

General Purpose Series Models Include:

• Compressor pump

• ASME air receiver with safety valve

• Electric motor

• Pressure switch

Quick Reference

Recommended Oil (2 Options)

Single viscosity SAE 30 ISO100 nondetergent compressor oil.
10W30 synthetic oil such as Mobil 1®.

Oil Capacity

Approximately 18 ounces

UNPACKING

Do not lift or move unit without appropriately rated equipment. Be sure

tubes or coolers. Do not use unit to lift other attached equipment.

After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Check for
loose, missing or damaged parts. Check to be sure all supplied accessories are enclosed with the unit. In case of
questions, damaged or missing parts, please visit www.jettools.com for customer assistance.

Do not operate unit if damaged during shipping, handling or use. Damage

the unit is securely attached to lifting device used. Do not lift unit by holding onto

may result in bursting and cause injury or property damage.

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

Required Items - Not Included

• Oil

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

1

SAFETY /

SPECIFICATIONS GETTING STARTED

GENERAL SAFETY INSTRUCTIONS

Safety Guidelines

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.

Notice indicates important information, that if not followed, may cause

damage to equipment.

IMPORTANT: Information that requires special attention.

Safety Symbols

The following Safety Symbols appear throughout this manual to alert you to important safety hazards and
precautions.

MANUAL

ASSEMBLY /

INSTALLATION

Wear Eye
and Mask
Protection

Risk of
Fumes

Read
Manual
First

Risk of
Pressure

Risk of
Fire

Risk of
Shock

Risk of
Moving
Parts

Risk of
Hot Parts

Risk of
Explosion

California Proposition 65

This product or its power cord may contain chemicals known to the State

hands after handling.

You can create dust when you cut, sand, drill or grind materials such as wood,

chemicals known to cause cancer, birth defects, or other reproductive harm. Wear protective gear.

of California to cause cancer and birth defects or other reproductive harm. Wash

paint, metal, concrete, cement, or other masonry. This dust often contains

Important Safety Information

Please read and save these instructions. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or property
damage! Retain instructions for future reference.

This manual contains important safety, operational and maintenance information. If you have any questions,
please visit www.jettools.com for customer assistance.

Since the air compressor and other components (material pump, spray guns, filters, lubricators, hoses, etc.)
used make up a high pressure pumping system, the following safety precautions must be observed at all times:

2

MANUAL

Important Safety Information (Continued)

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, the air compressor/pump will need to be
fitted with suitable in-line safety and alarm equipment. This additional equipment is necessary to
properly filter and purify the air to meet minimal specifications for Grade D breathing as described
in Compressed Gas Association Commodity Specification 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 shall be voided, and the
manufacturer disclaims any liability whatsoever for any loss, personal injury or damage.

General Safety

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

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

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

• Keep visitors away and NEVER allow children in the work area.

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

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

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

• Check all fasteners at frequent intervals for proper tightness.

Motors, electrical equipment and controls can cause electrical arcs that will

ignite a flammable gas or vapor. Never operate or repair in or near a flammable

gas or vapor. Never store flammable liquids or gases in the vicinity of the compressor.

Never operate compressor without a beltguard. This unit can start automatically

without warning. Personal injury or property damage could occur from contact

with moving parts.

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

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

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

• Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/or burns.

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

• To reduce fire hazard, keep engine/motor exterior free of oil, solvent, or excessive grease.

An ASME code safety relief valve with a setting no higher than the Maximum

or in the tank for this compressor. The ASME safety valve must have sufficient flow and pressure
ratings to protect the pressurized components from bursting. The flow rating can be found in the parts
manual. The safety valve in the intercooler does not provide system protection.

Maximum operating pressure is 175 psi for two-stage compressors. Do not

Allowable Working Pressure (MAWP) of the tank MUST be installed in the air lines

operate with pressure switch or pilot valves set higher than 175 psi (two-stage).

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

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

3

SAFETY /

SPECIFICATIONS GETTING STARTED

ASSEMBLY /

INSTALLATION

Important Safety Information (Continued)

Never use plastic (PVC) pipe for compressed air. Serious injur y or death could

Never attempt to repair or modify a tank! Welding, drilling or any other

Always replace worn, cracked or damaged tanks.

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

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

result.

modification will weaken the tank resulting in damage from rupture or explosion.

Drain liquid from tank daily.

Spraying Precautions

Do not spray flammable materials in vicinity of open flame or near

• Do not smoke when spraying paint, insecticides, or other flammable substances.

• Use a face mask/respirator when spraying and spray in a well ventilated area to prevent health and fire
hazards.

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

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

ignition sources including the compressor unit.

Save These Instructions

Do Not Discard

The DANGER, WARNING, CAUTION, and NOTICE 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.

4

Getting To Know Your Compressor

Compressor Pump

Tank Pressure

Gauge

Air Filter

Beltguard

Motor

Pressure Switch

Pressure Relief
Valve

Air Outlet

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

Figure 1 - Compressor Features

Manual Tank Drain

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

5

SAFETY /

SPECIFICATIONS GETTING STARTED

SPECIFICATIONS

JCP-801

Stock Number 506801
Motor HP 5
Power 230
Phase 1
Displacement CFM 17.3
Air Delivery CFM 13.7 @ 175 PSI
Max PSI 175
Pump RPM 1190
Tank Capacity 80
Unit Weight 460 lb
Amp Draw 22
Max Duty Cycle 80/20
Tank Outlet 3/4 (F) NPT
Tank MAWP 200 PSI

ASSEMBLY /

DIMENSIONS

INSTALLATION

Length 35 inches
Width 27 inches
Height 71 inches

BOLT DOWN PATTERN

11.69

in.

27.00

JCP-801

in.

11.69

120.00

in.

6.75

in.

o

13.50

in.

6

INSTALLATION INSTRUCTIONS

Disconnect, tag and lock out power source then release all pressure from the

Do not lift or move unit without appropriately rated equipment. Be sure the unit is

coolers. Do not use unit to lift other attached equipment.

system before attempting to install, service, relocate or perform any maintenance.

securely attached to lifting device used. Do not lift unit by holding onto tubes or

Never use the wood shipping skids for mounting the compressor.

Picking the Location

Install and operate unit at least 24 inches from any obstructions in a
clean, well ventilated area. The surrounding air temperature should
not exceed 100° F. This will ensure an unobstructed flow of air to
cool compressor and allow adequate space for maintenance.

Do not locate the compressor air inlet

or any other source of contamination.

near steam, paint spray, sandblast areas

NOTE: If compressor operates in a hot, moist environment, supply
compressor pump with clean, dry outside air. Supply air should be
piped in from external sources.

Tank Mounting

The tank should be bolted into a flat, even, concrete floor or on a
separate concrete foundation. Vibration isolators should be used
between the tank leg and the floor.

When using isolator pads, do not draw bolts tight. Allow the pads
to absorb vibrations. When isolators are used, a flexible hose or
coupling should be installed between the tank and service piping.

Failure to properly install the tank can

possible bursting.

lead to cracks at the welded joints and

≥ 24 inches

≥ 24

inches

Figure 2 - Location

≥ 24 inches

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

Piping

Never use plastic (PVC) pipe for

could result.

Any tube, pipe or hose connected to the unit must be able to
withstand the temperature generated and retain the pressure. All
pressurized components of the air system must have a pressure
rating of 200 psi or higher. Incorrect selection and installation of any
tube, pipe or hose could result in bursting and injury. Connect piping system to tank using the same size fitting as
the discharge port.

compressed air. Serious injury or death

Figure 3 - Isolator Pad

Minimum Pipe Size For Compressed Air Line

Length Of Piping System

CFM

25 feet 50 feet 100 feet 250 feet

10 1/2 inch 1/2 inch 3/4 inch 3/4 inch
20 3/4 inch 3/4 inch 3/4 inch 1 inch
40 3/4 inch 1 inch 1 inch 1 inch
60 3/4 inch 1 inch 1 inch 1 inch

100 1 inch 1 inch 1 inch 1-1/4 inch

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

7

SAFETY /

SPECIFICATIONS GETTING STARTED

ASSEMBLY /

INSTALLATION

INSTALLATION INSTRUCTIONS (CONTINUED)

Installing A Shut-Off Valve

A shut-off valve should be installed on the discharge port of the tank to control the air flow out of the tank. The
valve should be located between the tank and the piping system.

Never install a shut-off valve between the compressor pump and the tank.

discharge piping.

Personal injury and/or equipment damage may occur. Never use reducers in

When creating a permanently installed system to distribute compressed
air, find the total length of the system and select pipe size from the chart.
Bury underground lines below the frost line and avoid pockets where
condensation can gather and freeze.

Apply air pressure to the piping installation and make sure all joints are
free from leaks BEFORE underground lines are covered. Before putting
the compressor into service, find and repair all leaks in the piping, fittings
and connections.

Figure 4 - Shut-off Valve

Wiring

All wiring and electrical connections must be performed by a qualified electrician

local and national codes.

Wiring must be installed in accordance with National Electrical Code and local codes and standards that have
been set up covering electrical apparatus and wiring. These should be consulted and local ordinances observed.
Be certain that adequate wire sizes are used, and that:

1. Service is of adequate ampere rating.

2. The supply line has the same electrical characteristics (voltage, cycles and phase) as the motor. Refer to
motor name plate for electrical ratings and specifications.

3. The line wire is the proper size and that no other equipment is operated from the same line. The chart gives
minimum recommended wire sizes for compressor installations.

familiar with induction motor controls. Installations must be in accordance with

Overheating, short circuiting and fire damage will result from inadequate wiring.

Minimum Wire Size (Use 75°C Copper Wire)

Make sure voltage is correct with the motor wiring.
NOTE: If using 208 volts single phase, make sure the motor name plate states it is rated for 208 volts

single phase. 230 volt single phase motors do not work on 208 volts unless they have the 208 volt
rating.

Single Phase

HP Amps 230V

SPL up to 22.0 10 AWG

5.0 8 AWG

Recommended wire sizes may be larger than the minimum set up by local ordinances. If so, the
larger size wire should be used to prevent excessive line voltage drop. The additional wire cost is
very small compared with the cost of repairing or replacing a motor electrically “starved” by the
use of supply wires which are too small.

8

INSTALLATION INSTRUCTIONS (CONTINUED)

Grounding

Improperly grounded electrical

components are shock hazards.
Make sure all the components are properly
grounded to prevent death or serious injury.

This product must be grounded. Grounding reduces the
risk of electrical shock by providing an escape wire for
the electric current if short circuit occurs. This product
must be installed and operated with a power cord or
cable that has a grounding wire.

Breakers and Fuses

The entire electrical system should be checked by a
certified electrician. Time delay breakers and fuses are
required for this compressor. A tripped breaker or blown
fuses may indicate a direct short to ground, high current
draw, improper wiring, incorrect fuse or breaker size
and/or type. This needs to be evaluated by a certified
electrician.

Ground

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

L1

Motor

L2

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

Figure 5 - Wiring Diagram

9

SAFETY /

SPECIFICATIONS GETTING STARTED

ASSEMBLY /

INSTALLATION

INSTALLATION INSTRUCTIONS
(CONTINUED)

Installing Air Inlet Filter

Screw supplied air inlet filter into inlet port of cast iron pump
as indicated in Figure 6.

Lubrication

This unit contains no oil.

Before operating compressor, fill

to the center of the sight gauge (see Figure 6).

Using any other type of oil may

shorten pump life and damage

valves.

Recommended Oil (2 Options)

Single viscosity SAE 30 ISO100 nondetergent
compressor oil.

10W30 synthetic oil such as Mobil 1®.

Oil Capacity

Approximately 18 ounces

Fill the pump with oil to the center of the sight gauge
using oil fill opening (see Figure 6). Do NOT fill the

pump through the breather cap opening as this may
cause oil to leak and spray out during operation.

NOTE: Some residual oil may still be in the pump from
factory testing leaving a thin coat on the sight gauge;
however, there is not enough oil to operate the unit.

Full
Low

Sight Gauge

Inlet Filter

Oil Fill

Breather Cap

10

Oil Drain Plug

Figure 6

OPERATING INSTRUCTIONS

IMPORTANT: Check motor rotation before operating the compressor.
All lubricated compressor pumps discharge some condensed water and oil with the compressed air. Install

appropriate water/oil removal equipment and controls as necessary for the intended application.

Failure to install appropriate water/oil removal equipment may result in

damage to machinery or workpiece.

Guarding

All moving parts must be guarded. All electrical covers must be installed before turning on the power.

Recommended Break-In Period

The compressor should be run continuously for one hour to allow proper seating of the piston rings.

1. Open drain cock completely and run the compressor for 60 minutes.

2. Turn off the compressor and close drain cock. The compressor is now ready for use.

Pressure Switch, Start - Stop

NOTE: This compressor has a maximum operating pressure of

175 PSI for two-stage compressors or 135 PSI for single stage
compressors. Do not alter pressure settings on control components
above this limit.

The compressor unit starts and stops based on preset pressure switch
settings. The pressure switch contains an unloader which is a small
valve that vents air to allow the motor to start easily (See Figure 7).

Crankcase Breather

During severe operating conditions or initial start-up, some oil may
accumulate at the crankcase breather opening. This is normal and
will diminish as the pump accumulates run time and the piston rings
become fully seated.

The belt guard provided must be installed before operating the unit.

To tank pressure

Figure 7 - Pressure Switch

Unloader

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

Draining Tank

Condensation must be drained from the tank daily.

Duty Cycle

Each pump on this compressor is designed to operate
up to 75% of the time. Long-term or on-time operation
over 75% could decrease the life of the pump and
motor.

Figure 8 - Manual Tank Drain

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

11

SAFETY /

SPECIFICATIONS GETTING STARTED

ASSEMBLY /

INSTALLATION

TROUBLESHOOTING CHART

Symptom Possible Cause(s) Corrective Action

Motor hums and runs
slowly or not at all

Reset mechanism
cuts out repeatedly or
fuses blow repeatedly

Excessive noise in
operation

Milky oil in oil
crankcase

Excessive oil
consumption or oil in
air lines

Water in discharge air 1. Excessive water in tank 1. Drain tank

Air blowing out of inlet 1. Broken first stage inlet valve (two-

Insufficient pressure 1. Air demand too high 1. Limit air usage

Tank does not hold
pressure when
compressor is off and
shutoff valve is closed

1. Low voltage or no voltage 1. Check with voltmeter, check overload relay in magnetic starter or reset

2. Shorted or open motor winding 2. Replace motor

3. Malfunctioning check valve or
unloader valve

4. Malfunctioning pressure switch ­contacts will not close

1. Pressure switch set too high 1. Replace pressure switch

2. Malfunctioning check valve 2. Clean or replace faulty valve

3. Incorrect fuse size or magnetic starter
heaters

4. Malfunctioning motor 4. Replace motor

5. Loose Wiring 5. Check all electrical connections

1. Loose pulley, flywheel, belt, belt
guard, etc

2. Lack of oil in crankcase 2. Check for damage to bearings, replenish oil

3. Compressor floor mounting loose 3. Shim to level and tighten or place on islolator pads

4. Malfunctioning check valve 4. Replace check valve

5. Unit not on vibration pads 5. Install vibration pads under compressor feet

1. Low usage of compressor - water is
condensing in the crankcase

2. Wrong type of oil 2. Do not use SAE-30 automotive type oil. Using the wrong oil can cause

3. Improper environment 3. Unit should not be installed in a poorly vented area or exposed to

4. Rotation incorrect 4. Check to make sure the compressor is running the direction of the

5. Slight leakage of tank check valve 5. Air cools and condensates, then leaks back into the pump. Draining tank

1. Be sure there is a problem 1. Diagnose oil contamination problems by testing the discharge air or

2. Restricted air intake 2. Clean or replace air filter

3. Wrong oil viscosity 3. Drain oil. Refill with oil of proper viscosity

4. Worn piston rings 4. Replace rings

5. Oil leaks 5. Tighten bolts, replace gaskets or o-rings

6. Scored cylinder 6. Replace cylinder

2. Hot, humid weather 2. Purchase dryer

stage unit)

2. Broken inlet valve (single stage unit) 2. Replace valve assembly

2. Leaks or restrictions in hoses or
piping

3. Slipping belts 3. Tighten belts

1. Worn check valve 1. Replace check valve

2. Check all connections and fittings for
tightness

3. Check tank for cracks or pin holes 3. Replace tank. Never repair a damaged tank

switch on motor. If overload or reset switch trips repeatedly, find and
correct the cause. See next item

3. Replace check valve or unloader valve

4. Repair or replace pressure switch

3. Be sure that fuses and heaters are rated properly

1. Tighten

1. Run the compressor continuously for 1 hour. The heat generated during
this running period will evaporate the moisture out of the oil

various problems with the pump and will void the warranty. Only use the
oils that the operating manual recommends

extreme cold or hot conditions. Normal operating range should be
between 32°F and 100°F

flywheel arrow. Air flow should be so that the flywheel directs air across
the head of the pump. Standing in front of the compressor (non-belt
guard side) air should flow back to front

of air after use will normally take care of this situation

measuring oil consumption from the crankcase

1. Replace valve assembly

2. Check for leaks or restriction in hose or piping

Do not disassemble check valve with air

2. Tighten

in tank

12

Symptom Possible Cause(s) Corrective Action

Excessive belt wear.
(Light dust from start
is normal. Worn belts
separate at layers)

Tank pressure builds
slowly

Tank pressure
builds up quickly on
compressor

ASME safety valve
pops open while
compressor is running

Pressure switch
continuously blows air
out the unloader valve

Pressure switch
unloader valve does
not release air when
the unit shuts off

Interstage safety valve
pops off while the unit
is running

Interstage safety valve
pops off after the unit
shuts off

1. Pulley out of alignment 1. Realign motor pulley

2. Belts too tight or too loose 2. Adjust tension

1. Dirty air filter 1. Clean or replace filter element

2. Blown cylinder head gasket 2. Install new gasket

3. Worn/broken intake/discharge valves 3. Install new valve plate assembly

4. Air leaks 4. Tighten joints

Excessive water in tank Drain tank, check speed. See Performance table

1. Pressure switch setting to high 1. Replace pressure switch

2. Malfunctioning ASME safety valve 2. Replace ASME safety valve

3. Pressure switch contacts welded 3. Replace pressure switch

Malfunctioning check valve Replace the check valve if the unloader valve bleeds off constantly

Malfunctioning unloader valve on
pressure switch

1. Head gasket or the gasket in the
valve plate assembly blown

2. Valve not seating properly 2. Replace valve plate and gaskets

3. Malfunctioning safety valve 3. Replace safety valve

Malfunctioning tank check valve Replace the check valve

Replace the pressure switch if the unit does not hiss for a short period
of time when the unit shuts off

1. Replace valve plate and gaskets

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

13

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

SAFETY /

SPECIFICATIONS GETTING STARTED

MAINTENANCE AND INSPECTION INSTRUCTIONS

Disconnect, tag and lock out power source then release all pressure from the

system before attempting to install, service, relocate or perform any maintenance.

In order to maintain efficient operation of the compressor system, check the air filter and oil level before each
use. The ASME safety valve should also be checked daily (see Figure 9). Pull ring on safety valve and allow the
ring to snap back to normal position. This valve automatically releases air if the tank pressure exceeds the preset
maximum. If air leaks after the ring has been released, or the valve is stuck and cannot be actuated by the ring,
the ASME safety valve must be replaced.

Figure 9 - ASME Safety Valve

ASSEMBLY /

INSTALLATION

Do not tamper with the ASME safety valve.

Tank

Never attempt to repair or modify a tank! Welding, drilling or any other

Always replace worn, cracked or damaged tanks.

The tank should be carefully inspected at a minimum of once a year. Look for cracks forming near the welds. If a
crack is detected, remove pressure from tank immediately and replace.

modification will weaken the tank resulting in damage from rupture or explosion.

Drain liquid from tank daily.

Compressor Lubrication

See Installation. Add oil as required. The oil should be changed every three months or after every 500 hours of
operation; whichever comes first.

If the compressor is running under humid conditions for short periods of time, the humidity will condense in the
crankcase and cause the oil to look creamy. Oil contaminated by condensed water will not provide adequate
lubrication and must be changed immediately. Using contaminated oil will damage bearings, pistons, cylinders
and rings and is not covered under warranty. To avoid water condensation in the oil, periodically run the
compressor with tank pressure near 150 psi for two-stage compressors or 120 psi for single stage compressors
by opening the drain cock or an air valve connected to the tank or hose. Run the pump for an hour at a time at
least once a week or more often if the condensation reoccurs.

IMPORTANT: Change oil after first 50 hours of operation.

14

Air Filter

Never run the compressor pump without an intake air filter or with
a clogged intake air filter. The air filter element should be checked
monthly (see Figure 10). Operating compressor with a dirty filter can
cause high oil consumption and increase oil contamination in the
discharge air. If the air filter is dirty it must be replaced.

Figure 10

MAINTENANCE AND INSPECTION INSTRUCTIONS (CONTINUED)

Intercooler

Intercooler fins are sharp, always wear gloves and use care when

Weekly, check the intercooler to be sure all fittings are secure and tight. Clean all dirt, dust and other
accumulations from the intercooler fins.

you clean or work near the intercooler.

Components

Turn off all power and clean the cylinder head, motor, fan blades, air lines, intercooler and tank on a monthly
basis.

Belts

Lock out and tag the power then release all pressure from the tank to prevent

Check belt tension every 3 months. Adjust belt tension to allow 3/8 inch to 1/2 inch deflection with normal thumb
pressure. Also, align belts using a straight edge against the face of the flywheel and touching the rim on both
sides of the face. The belts should be parallel to this straight edge (see Figure 11). Dimension A should be the
same as B and C to ensure proper alignment of the belts.

Slots in the bed-plate allow for sliding the motor back and forth to adjust belt tension.

unexpected movement of the unit.

Motor

Motor Drive
Pulley

A B

Air Compressor

Flywheel

Straight Edge

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

Setscrew

C

Figure 11 - Top View

Maintenance Schedule

Operation Daily Monthly 3 Months

Check Safety Valve

Drain Tank

Check Oil Level

Clean or Change Air Filter

Check Intercooler

Clean Unit Components

Check Belt Tightness

Change Oil (see Figure 6)

l

l

l

l

l

l

l

l

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

15

REPAIR PARTS ILLUSTRATION FOR JCP-801

12

14

SAFETY /

SPECIFICATIONS GETTING STARTED

ASSEMBLY /

INSTALLATION

11

2

13

8

21

16

25

24

5

29

7

4

9

19

18

17

20

3

6

8

8

15

27

26

28

23

31

30

22

10

1

For Repair Parts, visit www.jettools.com to find your local distributor

24 hours a day – 365 days a year

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

16

REPAIR PARTS LIST FOR JCP-801

Ref.
No. Description Part Number: Qty.

1 AIR RECEIVER, 80 GALLON VERTICAL JCP801-001 1
2 COMPRESSOR PUMP, 5HP 2-STAGE JCP801-002 1
3 MOTOR, 5HP 208-230V 1PH JCP801-003 1
4 PULLEY, 5.7PD X 7/8 IN. BORE JCP801-004 1
5 HEX HEAD CAP SCREW, 7/16 IN.-14 X 1.5 IN. - 4
6 HEX HEAD CAP SCREW, 5/16 IN.-18 X 0.75 IN. - 4
7 WASHER, 7/16 IN. (ID 0.5 IN. X OD 1.25 IN.) - 4
8 WASHER, 5/16 IN. (ID 0.375 IN. X OD 0.875 IN.) - 12
9 HEX NUT, 7/16 IN.-14 - 4
10 SPINLOCK NUT, 5/16 IN.-18 - 4
11 BELT, A62 - 1
12 BELT GUARD BACK JCP801-005 1
13 SELF TAPPING HEX HEAD SCREW, 5/16 IN.-12 - 4
14 BELT GUARD FRONT JCP801-006 1
15 BELT GUARD RETAINING CLIPS JCP801-007 4
16 EXHAUST TUBE JCP801-008 1
17 CHECK VALVE JCP601-007 1
18 FERRULE, 1/2 IN. - 1
19 COMPRESSION NUT, 1/2 IN. - 1
20 QUICK CONNECT, 1/8 IN.NPT X 1/4 IN.TUBE JCP601-008 1
21 COMPRESSION FITTING, 1/2 IN. - 1
22 TANK DRAIN, 3/8 IN. NPT JCP801-009 1
23 NIPPLE, 1/4 IN. NPT X 1.5 IN. - 1
24 PRESSURE SWITCH JCP801-010 1
25 GAUGE, 300PSI JCP601-011 1
26 SAFETY VALVE, 200PSI JCP801-011 1
27 SELF TAPPING HEX HEAD SCREW, #8-0.375 IN. - 2
28 CORD STRAIN RELIEF - 1
29 WIRE NUT, 18-10AWG - 2
30 PTFE TUBE, 1/4 IN. X 13.5 IN. - 1
31 MOTOR CORD JCP601-018 1

Not Shown:

32 GENERAL WARNING DECAL LM000184 1
33 JET LOGO 7-1/4 IN.H X 17 IN.W LM000173 1
34 ID LABEL JCP-801 LM000175 1

SPECIFICATIONS GETTING STARTED

SAFETY /

INSTALLATION

ASSEMBLY /

17

MAINTENANCE /

REPAIRTROUBLESHOOTINGOPERATION

GETTING STARTED

REPAIR PARTS ILLUSTRATION FOR JCP-801

SAFETY /

ASSEMBLY /

SPECIFICATIONS

INSTALLATION

19

20

60

14

56

58

57

21

68

61

62

22

23

4

63

24

11

29, 30

31

32

33

34

35

36

37

38

39

23

40, 41

1

3

2

64

65

66

67

25

10

26

27

28

9

11

42

43

50

44

10

51

45

12

13

15, 16

17

18

8

7

6

5

54

46

47

53

48

49

55

59

52

TROUBLESHOOTING OPERATION

MAINTENANCE /

For Repair Parts, visit www.jettools.com to find your local distributor

24 hours a day – 365 days a year

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

REPAIR

18

REPAIR PARTS LIST FOR JCP-801

GETTING STARTED

Ref
No Description Part Number Qty

1 1/4” NPT Drain plug

2 Oil level gauge

3 Oil level gauge o-ring

4 Crankcase

5 Flywheel

6 Flat washer

7 Lock washer

8 Bolt, M12

9 Hex Capscrew, M10x80

10 Spring washer, M10

11 Intercooler tting without tapped hole -- 2

12 Cylinder head (low pressure)

13 Head gasket (LP)

14 Valve plate assembly ≠ 1

21 Valve plate - cylinder gasket (LP)

22 Cylinder (LP) -- 1

23 Cylinder-crankcase gasket

24 Intercooler assembly with are nuts -- 1

25 Hex bolt, M10x65

26 Cylinder head (high pressure) -- 1

27 Head gasket (HP)

28 Valve plate assembly (HP)

35 Valve plate - cylinder gasket (HP)

36 Cylinder (HP) -- 1

37 Nut

38 Spring washer

39 Stud bolt

40 Fill plug

41 Fill plug o-ring

42 Oil seal

43 Compression ring ‡ 1

44 Compression ring ‡ 1

45 Oil ring ‡ 2

46 Piston ‡‡ 1

47 Wrist pin ‡‡ 1

48 Retainer clip

49 Key

50 Ball bearing

51 Dipper

52 Lock washer

53 Dipper retaining screw, M4x10

54 Wrist pin

55 Connecting rod † 1

56 Compression ring ∞ 3

57 Oil ring ∞ 1

58 Piston

59 Crankshaft

u

u t

u t w

u

n

s v

s v

s v

v

v

w

≠ w

≠ w

w

v

w I

I

w I

v

v

v

u o

u o

u w

‡‡ m

n

l

H †

H †

H †

m

m

l

1

1

1

1

1

1

1

1

4

8

1

1

1

2

4

1

1

1

8

8

8

1

1

1

2

1

1

1

1

1

1

1

1

Ref
No Description Part Number Qty

60 Connecting rod (HP)

61 Ball bearing

62 Rear bearing plate †† 1

63 Bearing cap gasket

64 Breather assembly JCP801-012 1

65 Bearing cap †† 1

66 Copper washer

67 Bolt

68 Air lter assembly JCP801-013 1

69 Beltguard bracket JCP801-014 1

NOT SHOWN

Air lter element JCP801-015 1

REPAIR KITS AND ACCESSORIES

Flywheel bolt kit JCP801-016 1

s

Flywheel with key JCP801-017 1

n

Crankshaft assembly with bearings JCP801-018 1

l

Crankcase assembly with oil seal, oil

u

level gauge, drain plug, and ll plug

Oil level gauge with o-ring JCP801-020 1

t

Fill plug with o-ring JCP801-021 1

o

High pressure connecting rod assembly

H

with dipper

† Low pressure connecting rod assembly

with dipper

†† Bearing cap with bafe JCP801-024 1

‡ Piston ring kit (LP) JCP801-025 1

‡‡ Piston set (LP) JCP801-026 1

Piston set (HP) JCP801-027 1

m

∞ Piston ring kit (HP) JCP801-028 1

≠ Valve plate kit (LP) JCP801-029 1

Gasket, oil seal and o-ring kit (except

w

valve plate to plate gasket)

Assembly fastener set JCP801-031 1

v

Valve plate kit (HP) JCP801-032 1

I

-- Not Available

H

l

w

v

v

JCP801-019 1

JCP801-022 1

JCP801-023 1

JCP801-030 1

1

1

1

1

1

SPECIFICATIONS

SAFETY /

INSTALLATION

ASSEMBLY /

TROUBLESHOOTINGOPERATION

MAINTENANCE /

REPAIR

19