Porter Cable CPL55GH8W Owner’s Manual

Instruction

Oillube

manual

MODEL CPL55GH8W

Compressor

IMPORTANT

o learn more about Porter-Cable

visit our website at:

http://www.porter-cable.com

PORTER+CRBLEo

PROFESSIONAL POWER TOOLS

Please make certain that the person who is to use

this equipment carefully reads and understands

these instructions before starting operations.

The Model and Serial No plate is located on the frame Record these numbers in the spaces below and retain for future reference

Model No

Type

Serial No

SAFETY GUIDELINES - DEFINITIONS

This manual contains information that is important for you to know and understand. This infor

mation relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you recognize this information, we use the symbols below Please read the manual and pay attention to these sections

DANGER indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury,

CAUTION indicates a potentially hazardous situation which, if not

avoided, _ result in minor or rnodera'_e i_.

[R.'_li=i [,]_r

WARNING indicates a potentially hazardous situation which, if not

avoided, could result in death or S@J'io_ injury

Call our Toll Free Number 1-888-559-8550, to obtain the location of the nearest Autho-

rized Service Center for ordering repair parts and for warranty repairs. When ordering repair parts from your Iocat Authorized Service Center. always gwe the

following information:

• Model number of your compressor

• Part number and description of the item you wish to purchase

Retain Original Sales Receipt as Proof of Purchase for Warranty Repair Work.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not

avoided, may result in I_r_erty damage.

IMPORTANT SAFETY INSTRUCTIONS

This product is not equipped with a spark arresting muffler. If the product will be used around flammable materials, or on land covered with materials such as agricultural crops, forest, brush, grass, or other similar items,

then an approved spark attester must be installed and is legally required in the state of California. It is a violation of California statutes section 130050 and/or

sections 4442 and 4443 of the California Public Resources Code, unless the engine is equipped with a spark arrestor, as defined in section 4442, and maintained in effective working order. Spark arresters are also required on some

U. S. Forest service land and may also be legally required under other statutes

and ordinances.

This product may contain chemicals known to the state of California to cause

cancer, birth defects, or other reproductive harm. This warning is given in compliance with California Proposition 65, as detectable amounts of chemicals

subject to proposition 65 may be contained in this product.

READ AND FOLLOW ALL INSTRUCTIONS.

This tool was designed for certain applications PortepCable strongly recommends that this tool NOT be modified and/or used for any application other than for which it was designed. If you have any questions relative to its application DO NOT use the tool until you have wrJtten Porter-Cable and we have advised you.

Technical Service Manager

Porter-Cable Corporation 4825 Highway 45 North RO. Box 2468 Jackson, TN 38302 2468

2 _ NC,

IMPORTANT SAFETY INSTRUCTIONS (cont'd)

SAVE THESE INSTRUCTIONS _\ I

IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY

AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT.

HAZARD

RISK OF EXPLOSION OR FIRE i_ I

WHAT CAN HAPPEN

GASOLINE AND GASOLINE VAPORS CAN BECOME

IGNITED BY COMING INTO CONTACT WITH HOT

COMPONENTS SUCH AS THE MUFFLER, FROM

ENGINE EXHAUST GASES, OR FROM AN ELECTRICAL SPARK,

COMBUSTIBLE .MATERIALS WH]CH COME INTO CONTACT WITFI HOT ENGIN E PARTS CAN BECOME

IGNITED

UNATTENDED OPERATION OF THIS PRODUCT COULD RESULT IN PERSONAL INJURY OR

PROPERTY DAMAGE.

RISK OF BURSTING

AIR TANK: THE FOLLOWING CONDITIONS COULD LEAD TO A WEAKENING OF THE TANK, AND RESULT

IN A VIOLENT TANK EXPLOSION AND COULD CAUSE PROPERTY DAMAGE OR SERIOUS INJURY.

WHAT CAN HAPPEN

1 FAILURE TO PROPERLY DRAIN CONDENSED

WATER FROM THE TANK, CAUSING RUST AND THINNING OF THE STEEL TANK

2 MODIFICATIONS OR A_IEMPTED REPAIRS

TO THE TANK.

3 UNAUTHORIZED MODIFICATIONS TO THE

UNLOADER VANE, SAFETY VALVE, OR ANY

OTHER COMPONENTS WHICH CONTROL TANK PRESSURE.

4 EXCESSIVE VIBRATION CAN WEAKEN THE AIR

TANK AND CAUSE RUPTURE OR EXPLOSION.

EXCESSIVE VIBRATION WILL OCCUR iF THE COMPRESSOR IS NOT PROPERLY MOUNTED OR IF THE ENGINE

OPERATES ABOVE RECOMMENDED RPM

ATTACHMENTS & ACCESSORIES;

EXCEEDING THE PRESSURE RATING OF AIR TOOLS, SPRAY GUNS, AIR OPERATED

ACCESSORIES TIRES AND OTHER INFLATABLES CAN CAUSE THEM TO EXPLODE OR FLY APART

AND COULD RESULT IN SERIOUS INJURY

TURN ENGINE OFF AND ALLOW IT TO COOL

BEFORE ADDING FUEL TO THE TANK EQUIP AREA OF OPERATION WITH A FIRE EXTINGUISHER CERBEIED TO HANDLE GASOLINE OR FUEL FIRES

ADD FUEL OUTDOORS IN A WELL VENTILATED

AREA MAKE SURE THERE ARE NO SOURCES OF

IGNITION, SUCH AS CIGARETTES NEAR

REFUELING LOCATION

OPERATE COMPRESSOR IN A CLEAN DRY, WELL

VENTILATED AREA A MINIMUM QF FORTY EIGH]

INCHES FROM ANY BUILDING. OBJECT OR WALL

DO NOT OPERATE UNIT INDOORS OR IN ANY

CONFINED AREA.

STORE FUEL IN A SECURE LOCATION AWAY FROM

COMPRESSOR

ALWAYS REMAIN IN ATTENDANCE WITH THE

PRODUCT WHEN IT IS OPERATING.

DRAIN TANK DAILY OR AFTER EACH USE. iF TANK

DEVELOPS A [ EAK REPL_,CE IT IMMEDIATELY WITH A NEW TANK OR REPLACE THE ENTIRE COMPRESSOR

NEVER DRILL INTO, WELD, OR MAKE ANY MODIFICATIONS TO THE TANK OR ITS AI_ACH MENTS

THE TANK IS DESIGNED TO WITHSTAND SPECIFIC OPERATING PRESSURES NEVER MAKE ADJUSTMENTS OR PARTS SUBSTITUTIONS TO ALTER THE FACTORY SET OPERATING

PRESSURES.

DO NOT REMOVE THE STIFFENER BAR

CONNECTING THE COMPRESSOR PUMP ]O THE

ENGINE EXCEPT TO ADJUST BELT TENSION THEN

SECURELY TIGHTEN THE STIFFENER BAR NUTS

THIS BAR CONTROLS OUTFIT VIBRATION.

FOR ESSEN]IAL CONTROL OF AIR PRESSURE YOU

MUST INSTALL A PRESSURE REGULATOR AND

PRESSURE GAUGE TO THE AIR OUTLET OF YOUR

COMPRESSOR FOLLOW THE EQUIPMENT

MANUFACTURERS RECOMMENDATION AND

NEVER EXCEED THE MAXIMUM ALLOWABLE

PRESSURE RATINGOFAI_ACHMENTS NEVERUSE

COMPRESSOR TO INFLATE SMALL LOW-

PRESSURE OBJECTS SUCH AS CHILDREN'S

TOYS, FOOTBALLS, BASKETBALLS. ETC.

3 FNG

HOW TO PREVENT IT

IMPORTANT SAFETY INSTRUCTIONS (cont'd)

RISK FROM FLYING OBJECTS

WHAT CAN HAPPEN HOW TO PREVENT IT

THE COMPRESSED AIR STREAM CAN CAUSE SOFT TISSUE DAMAGE TO EXPOSED SKIN AND CAN PROPEL DIRT¸ CHIPS¸ LOOSE PARTICLES AND SMALL OBJECTS A1 HIGH SPEED¸ RESULTING IN PROPERTY DAMAGE QR PERSONAL INJURY¸

RISK TO BREATHING

WHAT CAN HAPPEN HOW TO PREVENT IT

BREATHING EXHAUST FUMES FROM ENGINE WILL CAUSE SERIOUS INJURY OR DEATH.

THE COMPRESSED AIR FROM YOUR COMPRESSOR IS NOT SAFE FOR BREATHING!

THE AIR STREAM MAY CONTAIN CARBON

MONOXIDE, TOXIC VAPORS OR SOLID PARTICLES

FROM THE TANK

SPRAYED MATERIALS SUCH AS PAINT PAINT SOLVENTS, PAINT REMOVER, INSECTICIDES,

WEED KILLERS. CONTAIN HARMFUL VAPORS AND

POISONS

ALWAYS WEAR ANSI Z87 1 APPROVED SAFETY GLASSES WITH SIDE SHIELDS WHEN USING THE COMPRESSOR

NEVER POINT ANY NOZZLE OR SPRAYER TOWARD ANY PART OF THE BODY OR AT OTHER PEOPLE OR ANIMALS

ALWAYS TURN THE COMPRESSOR OFF AND BLEED PRESSURE FROM THE AIR HOSE AND

TANK BEFORE ATTEMPTING MAINTENANCE, ATTACHING TOOLS OR ACCESSORIES

ALWAYS OPERATE AIR COMPRESSOR OUTSIDE IN A CLEAN, WELL VENTILATED AREA. AVOID ENCLOSED AREAS SLiCH ,\S GARAGES

BASEMENTS STORAGE SHEDS WHICH LACK A STEADY EXCHANGE Of AIR KEEP CHILDREN PETS AND OTHERS A_,AY FROM AREA OF OPERATION

NEVER INHALE AIR PROM THE COMPRESSOR EITHER DIRECTLY OR FROM A BREATHING DEVICE

CONNECTED TO THE COMPRESSOR

WORK IN AN AREA WITH GOOD CROSS- VENTILATION. READ AND FOLLOW THE SAFETY

INSTRUCTIONS PROVIDED ON THE LABEL OR SAFETY DATA SHEETS FOR THE MATERIAL YOU

ARE SPRAYING. USE A NIOSH/MSRA APPROVED

RESPIRATOR DESIGNED FOR USE WITH YOUR SPECIFIC APPLICATION

RISK FROM MOVING PARTS r_

WHAT CAN HAPPEN HOW TO PREVENT IT

THE ENGINE CAN START ACCIDENTALLY IF THE ALWAYS DISCONNECT THE SPARK PLUG AND FLYWHEEL IS TURNED BY HAND OR MOVED BY BLEED PRESSURE FROM THE TANK BEFORE

PULLING ON THE STARTER ROPE PERFORMING MAINTENANCE.

MOVING PARTS SUCH AS THE PULLEY FLYWHEEL ANDBE[, CAN CAUSE SERIOUS INJURY, IFTHEY

COME INTO CONTACT WI]H YOU DR YOUR CLOTHING

ATTEMPTING TO OPERATE COMPRESSOR WITH DAMAGED OR MISSING PARTS OR ATTEMPTING TO REPAIR COMPRESSOR WITH PROTECTIVE SHROUDS REMOVED CAN EXPOSE YOU TO MOVING PARTS AND (;AN RESULT IN SERIOUS

INJURY.

NEVER OPERATE THE COMPRESSOR WITH GUARDS OR COVERS WHICH ARE DAMAGED OR

REMQVED

ANY REPAIRS REQUIRED ON IHIS PRODUCT SHOULD BE PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL.

4 ENG

IMPORTANT SAFETY INSTRUCTIONS (cont'd)

RISK OF BURNS

WHAT CAN HAPPEN

TOUCHING EXPOSED METAL SUCH AS THE COMPRESSOR HEAD OR OUTLET TUBES OR CONTACT WITH HOT ENGINE PARTS, SUCH AS

TBE MUFFLER, CAN RESU_IN SERIOUSBURNS.

THE GASOLINE ENGINE, THE ENGINE MUFFLER, THE COMPRESSOR HEAD AND TUBING BECOME

VERY HOT DURING OPERATION

RISK OF FALLING

WHAT CAN HAPPEN

A PORTABLE COMPRESSOR CAN FALL FROM A TABLE, WORKBENCH OR ROOF CAUSING DAMAGE TO THE COMPRESSOR AND COULD

RESULT IN SERIOUS INJURY OR DEATH TO THE

OPERATOR OR BYSTANDERS.

RISK OF PROPERTY DAMAGE WHEN

TRANSPORTING COMPRESSOR

(Fire, Inhalation, Damage

to Vehicle Surfaces)

WHAT CAN HAPPEN

FUEL OR OIL CAN LEAK OR SPILL AND COULD

RESULT IN FIRE OR BREATHING HAZARD, SERIOUS INJURY OR DEATH CAN RESULT. FUEL OR OIL LEAKS WILL DAMAGE CARPET, PAINT OR OTHER SURFACES IN VEHICLES OR TRAILERS

Gsw*g9 -- 9/22/99

HOW TO PREVENT IT

NEVER TOUCH ANY EXPOSED METAL PARTS ON ENGINE OR COMPRESSOR DURING OR

IMMEDIATELY AFTER OPERATION ENGINE AND COMPRESSOR WILL REMAIN NOT FOR SEVERAL MINUTES AFTER OPERATION

DO NOT REACH AROUND PROTECTIVE SHROUDS OR ATTEMPT MAINTENANCE UNTIL UNIT HAS

BEEN ALLOWED TO COOL

HOW TO PREVENT IT

ALWAYS OPERATE COMPRESSOR IN A STABLE SECURE POSITION TO PREVENT ACCIDENTAL MOVEMENT OF THE UNIT NEVER OPERATE

COMPRESSOR ON A ROOF OR OTHER ELEVATED POSITION. USE ADDITIONAL AIR HOSE TO

REACH HIGH LOCATIONS.

HOW TO PREVENT IT

IF COMPRESSOR IS EQUIPPED WITH A FUEL SHUT- OFF VALVE, TURN THE VALVE TO THE OFF

POSITION BEFORE TRANSPORTING TO AVOID FUEL LEAKS. iF COMPRESSOR IS NOT EQUIPPED WITH A FUEL SHUT-OFF VALVE, DRAIN THE FUEL

FROM TANK BEFORE TRANSPORTING

TRANSPORT FUEL ONLY IN AN OSHA APPROVED

CONTAINER ALWAYS PLACE COMPRESSOR ON A

PROTECTIVE MAT WHEN TRANSPORTING TO PROTECT AGAINST DAMAGE TO VEHICLE FROM

LEAKS. REMOVE COMPRESSOR FROM VEHICLE IMMEDIATELY UPON ARRIVAL AT YOUR

DESTINATION.

5 ENG

GLOSSARY

CFM: Cubic feet per minut_ SCFM: Standard cubic feet per rninute;a unit of measure of air delivery

PSlG: Pounds per square Jncl_gauge; a unit of measure of pressure ASME: American Society of Mechanical Engineers; made, tested, inspected and

registered to meet the standards of ASME. California Code: Unit may comply with California Code 462 (¢)(2)/(M) (2).

Specification/mode/ label is on the side of the tank on units that comply with California Code.

Unloader Blow-Off Pressure: When the maximum tank pressure is obtained, the unloader valve will blow off This will cause the conqpressor to exhaust the air to

the atmosphere and not into the tank. This decreases the load on the engine and allows it to run at a near no load condition.

Unloader Reset Pressure: When the tank pressure drops to a pre determined point, the unloader valve closes The tank pressure will now increase until it

reaches the unloader blow-oft pressure. Code Certification: Products that bear one or more of the following marks: UL,

CUL, ETL, CETL, have been evaluated by OSHA certified independent safety laboratories and meet the applicable Underwriters Laboratories Standards for

Safety.

DUTY CYCLE

Porter-Cable air compressors should be operated eta not more than a 50% duty cycle This means an air compressor that pumps air more than 50% of one hour is

considered misuse, because the air compressor is undersized for the required air demand. Maximum compressor pumping time per hour is 30 minutes.

SPECIFICATIONS

Model No.

Engine Horsepower 5.5 Bore 2.875"

Stroke 2.0" Air Tank Capacity (Gallon) 8 Approximate Unloader Reset Pressure 110 PStG Approximate Unloader Blow-off Pressure 135 PSIG

SCFM @ 40 PSIG 12.0

SCFM @ 90 PSIG

IMPORTANT: See engine operator's manual for engine information.

6 _NG

CPL55GH8W

101

DESCRIPTION OF OPERATION

Air Compressor Pump (not shown): D Compresses air into the air tank. E C

Unloader Valve (not shown): When the maximum tank pressure is obtained, the

unloader valve will exhaust the compressed air to the atmosphere

(blow-off). When the tank pressure drops to a pre determined point, the unloader

valve closes and causes the tank pressure to increase. Safety Valve (C} Fig. 1: If the unloader Fig. 1

valve does not retease pressure when tank reaches "blow-off" pressure, the safety valve will protect against high pressure by "popping off" at its factory set pressure

(slightly higher than the pressure switch blow off setting). Outlet Pressure Gauge (D) Fig. 1: The outlet pressure gauge indicates theail

pressure available at the outlet side of the regulator This pressure is controlled by the regulator and is always less than or equal to the tank pressure.

Tank Pressure Gauge (El Fig. 1: The tank pressure gauge indicates the reserve a_r pressure in the tank.

Regulator (F} Fig. 1: Controls the air pressure shown on the outlet pressure gauge Puff the knob out and turn clockwise to increase pressure and counterclockwise to

decrease pressure, When the desired pressure is reached push knob in to lock in

place. Drain Valve (not shown}: A drain valve is located at the base of each air tank and

is used to drain condensation at the end of each use

Air Intake Filter (not shown}: This filter is designed to clean air coming into the

pump. This filter n3_ust,always be clean and ventilation openings free from obstructions. See "Maintenance".

Throttle Control (not shown): A throttle control has been rncorporated as an extra feature. When maximum tank pressure is reached and the unloader valve vents air.

it also activates a throttle control on the engine. This gas saving feature holds the engine at a factory-set idling speed until air pressure in the air tank drops to reset

pressure. It then reactivates the throttle control and accelerates the engine to full throttle.

INSTALLATION

_THE WHEEL AND HANDLES DO NOT PROVIDE ADEQUATE

CLEARANCE, STABILITY OR SUPPORT FOR PULLING THE COMPRESSOR UP

AND DOWN STAIRS OR STEPS. THE COMPRESSOR MUST BE LIFTED, OR

PUSHED UP A RAMP.

1. Push rubber handle grips (L), onto

handle tubes (M). Seat firmly. Use a

twisting motion to ease assembly. See

Fig. 2.

2. Position one

handle and grip

assembly into

clamp on left side of tank assembly, as shown in Fig. 2.

Align hole in handle

with hole in clamp. Inser_ bolt (N)

through the hole (in Fig. 2 clamp and handle). Thread nut (O) onto bolt. Using two 1/2" wrenches (not

furnished) tighten nut securely.

Repeat step 2 to assemble remaining handle and grip assembly to the clamp on the right side of tank assembly.

Using a 9/16" socket wrench (not furnished) remove the four bolts securing the

compressor to the shipping skid.

A. Place spacer (S) on flat side of a rubber foot (R). Place spacer and rubber

foot against compressor frame as shown in Figure 2.

B. Align hole in spacer and rubber foot with one of the smaller holes adjacent to

the holes where shipping skid was attached.

C. Insert one of the 1/4"-20 x 3/4" bolts (P), from the hardware package, and

using a 3/8" socket wrench (not furnished) tighten firmly.

D. Repeat A through C to install the three remain=ng rubber feet.

Location of the Air Compressor

EXHAUST FROM THE GASOLINE ENGINE CONTAINS

DEADLY CARBON MONOXIDE, WHICH IS ODORLESS AND TOXIC. OPERATE ENGINE ONLY IN WELL-VENTILATED AREAS.

The air compressor must be operated in a clean, dry, and well-ventilated area. The

air compressor's crankcase and head are designed with cooling fins to provide proper cooling. The fan blades of the compressor, the flywheel, must be kept clear

of obstructions that could interfere with the flow of air through the air intake filter.

Do not install the air compressor in a location where heat is excessive. If the humidity in the operating area is high, an air filter can be installed on the air outlet adapter 1o remove excessive moisture. This type air filter is not provided with this air compressor and must be purchased separately. Closely follow the instructions packaged with the filter for proper installation.

_Do not allow the air compressor to get wet if it is

installed outdoors.

8 ENG

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