Porter-Cable D24225-049-2 User Manual
Instruction
®
manual
ESPAÑOL: PÁGINA 27
FRANÇAIS: PAGE 53
Oil Lube Two Stage
Air Compressor
To learn more about Porter-Cable
visit our website at:
http://www.porter-cable.com
Copyright © 2004 Porter-Cable Corporation
CPLMC7580V2C
IMPORTANT
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.
Part No. D24225-049-2
SAFETY GUIDELINES - DEFINITIONS
This manual contains information that is important for you to know and understand. This information
relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS. To help you
recognize this information, we use the symbols below. Please read the manual and pay attention to
these sections.
Indicates an
imminently hazardous
situation which, if not avoided, will
result in death or serious injury
Indicates a potentially
hazardous situation
which, if not avoided, could
death or serious injury
result in
.
which, if not avoided, may
.
minor or moderate injury.
indicates a potentially hazardous
situation which, if not avoided, may
result in pr
Indicates a potentially
hazardous situation
result in
Used without the
safety alert symbol
operty damage.
IMPORTANT SAFETY INSTRUCTIONS
Some dust created by power sanding, sawing, grinding, drilling, and other
cause cancer, birth defects or other reproductive harm. Some example of these chemicals are:
G
lead from lead-based paints
G
crystalline silica from bricks and cement and other masonry products
G
arsenic and chromium from chemically-treated lumber
Your risk from these exposures varies, depending on how often you do this type of work. To reduce
your exposure to these chemicals: work in a well ventilated area, and work with approved safety
equipment, always wear MSHA/NIOSH approved, properly fitting face mask or respirator when using
such tools.
When using air tools, basic safety precautions should always be followed to reduce the risk of of
personal injury.
This tool was designed for certain applications. Porter-Cable 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 written Porter-Cable and we
have advised you.
construction activities contains chemicals known (to the State of California) to
READ AND FOLLOW ALL INSTRUCTIONS.
Technical Service Manager
Porter-Cable Corporation
4825 Highway 45 North
P.O. Box 2468
Jackson, TN 38302-2468
D24225
2- ENG
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN
SERIOUS INJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL
WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT.
HAZARD
RISK OF EXPLOSION OR FIRE
WHAT CAN HAPPEN
IT IS NORMAL FOR ELECTRICAL CONTACTS
WITHIN THE MOTOR AND PRESSURE SWITCH
TO SPARK.
IF ELECTRICAL SPARKS FROM
COMPRESSOR COME INTO CONTACT WITH
FLAMMABLE VAPORS, THEY MAY IGNITE,
CAUSING FIRE OR EXPLOSION.
RESTRICTING ANY OF THE COMPRESSOR
VENTILATION OPENINGS WILL CAUSE
SERIOUS OVERHEATING AND COULD CAUSE
FIRE.
UNATTENDED OPERATION OF THIS
PRODUCT COULD RESULT IN PERSONAL
INJURY OR PROPERTY DAMAGE. TO
REDUCE THE RISK OF FIRE, DO NOT ALLOW
THE COMPRESSOR TO OPERATE
UNATTENDED.
HOW TO PREVENT IT
ALWAYS OPERATE THE COMPRESSOR IN A
WELL VENTILATED AREA FREE OF
COMBUSTIBLE MATERIALS, GASOLINE OR
SOLVENT VAPORS.
IF SPRAYING FLAMMABLE MATERIALS,
LOCATE COMPRESSOR AT LEAST 20 FEET
AWAY FROM SPRAY AREA. AN ADDITIONAL
LENGTH OF HOSE MAY BE REQUIRED.
STORE FLAMMABLE MATERIALS IN A
SECURE LOCATION AWAY FROM
COMPRESSOR.
NEVER PLACE OBJECTS AGAINST OR ON
TOP OF COMPRESSOR. OPERATE
COMPRESSOR IN AN OPEN AREA AT LEAST
12 INCHES AWAY FROM ANY WALL OR
OBSTRUCTION THAT WOULD RESTRICT THE
FLOW OF FRESH AIR TO THE VENTILATION
OPENINGS.
OPERATE COMPRESSOR IN A CLEAN, DRY,
WELL VENTILATED AREA. DO NOT OPERATE
UNIT INDOORS OR IN ANY CONFINED AREA.
ALWAYS REMAIN IN ATTENDANCE WITH
THE PRODUCT WHEN IT IS OPERATING.
ALWAYS DISCONNECT ELECTRICAL POWER
BY MOVING PRESSURE SWITCH LEVER TO
THE OFF POSITION AND DRAIN TANK DAILY
OR AFTER EACH USE.
3- ENG
D24225
HAZARD
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.
1. FAILURE TO PROPERLY DRAIN
CONDENSED WATER FROM THE
TANK, CAUSING RUST AND THINNING
OF THE STEEL TANK.
2. MODIFICATIONS OR ATTEMPTED
REPAIRS TO THE TANK.
3. UNAUTHORIZED MODIFICATIONS TO
THE UNLOADER VALVE, SAFETY
VALVE, OR ANY OTHER COMPONENTS
WHICH CONTROL TANK PRESSURE.
4. EXCESSIVE VIBRATION CAN WEAKEN
THE AIR TANK AND CAUSE RUPTURE
OR EXPLOSION.
TTACHMENTS & ACCESSORIES:
A
EXCEEDING THE PRESSURE RATING OF AIR
TOOLS, SPRAY GUNS, AIR OPERATED
ACCESSORIES, TIRES AND OTHER
INFLATABLES CAN CAUSE THEM TO
EXPLODE OR FLY APART, AND COULD
RESULT IN SERIOUS INJURY.
HAZARD
RISK FROM FLYING OBJECTS
WHAT CAN HAPPEN
HOW TO PREVENT IT
DRAIN TANK DAILY OR AFTER EACH USE. IF
TANK DEVELOPS A LEAK, REPLACE IT
IMMEDIATELY WITH A NEW TANK OR REPLACE
THE ENTIRE COMPRESSOR.
NEVER DRILL INTO, WELD, OR MAKE ANY
MODIFICATIONS TO THE TANK OR ITS
ATTACHMENTS.
THE TANK IS DESIGNED TO WITHSTAND
SPECIFIC OPERATING PRESSURES. NEVER
MAKE ADJUSTMENTS OR PARTS
SUBSTITUTIONS TO ALTER THE FACTORY
SET OPERATING PRESSURES.
FOR ESSENTIAL CONTROL OF AIR
PRESSURE,YOU MUST INSTALL A PRESSURE
REGULATOR AND PRESSURE GAUGE TO THE
AIR OUTLET (IF NOT EQUIPPED) OF YOUR
COMPRESSOR. FOLLOW THE EQUIPMENT
MANUFACTURERS RECOMMENDATION AND
NEVER EXCEED THE MAXIMUM ALLOWABLE
PRESSURE RATING OF ATTACHMENTS. NEVER
USE COMPRESSOR TO INFLATE SMALL LOWPRESSURE OBJECTS SUCH AS CHILDREN’S
TOYS, FOOTBALLS, BASKETBALLS, ETC.
WHAT CAN HAPPEN
THE COMPRESSED AIR STREAM CAN CAUSE
SOFT TISSUE DAMAGE TO EXPOSED SKIN
AND CAN PROPEL DIRT, CHIPS, LOOSE
PARTICLES AND SMALL OBJECTS AT HIGH
SPEED, RESULTING IN PROPERTY DAMAGE
OR PERSONAL INJURY.
D24225
HOW TO PREVENT IT
ALWAYS WEAR ANSI Z87.1 APPROVED
SAFETY GLASSES WITH SIDE SHIELDS WHEN
USING THE COMPRESSOR.
NEVER POINT ANY NOZZLE OR SPRAYER
TOWARD ANY PART OF THE BODY OR AT
OTHER PEOPLE OR ANIMALS.
ALWAYS TURN THE COMPRESSOR OFF AND
BLEED PRESSURE FROM THE AIR HOSE AND
TANK BEFORE ATTEMPTING MAINTENANCE,
ATTACHING TOOLS OR ACCESSORIES.
4- ENG
HAZARD
RISK OF ELECTRICAL SHOCK
WHAT CAN HAPPEN
YOUR AIR COMPRESSOR IS POWERED BY
ELECTRICITY. LIKE ANY OTHER
ELECTRICALLY POWERED DEVICE, IF IT IS
NOT USED PROPERLY IT MAY CAUSE
ELECTRIC SHOCK.
REPAIRS ATTEMPTED BY UNQUALIFIED
PERSONNEL CAN RESULT IN SERIOUS
INJURY OR DEATH BY ELECTROCUTION.
ELECTRICAL GROUNDING: FAILURE TO
PROVIDE ADEQUATE GROUNDING TO THIS
PRODUCT COULD RESULT IN SERIOUS
INJURY OR DEATH FROM ELECTROCUTION.
SEE GROUNDING INSTRUCTIONS.
HAZARD
RISK TO BREATHING
WHAT CAN HAPPEN
THE COMPRESSED AIR DIRECTLY FROM
YOUR COMPRESSOR IS NOT SAFE FOR
BREATHING. THE AIR STREAM MAY
CONTAIN CARBON MONOXIDE, TOXIC
VAPORS, OR SOLID PARTICLES FROM THE
TANK. BREATHING THESE CONTAMINANTS
CAN CAUSE SERIOUS INJURY OR DEATH.
SPRAYED MATERIALS SUCH AS PAINT, PAINT
SOLVENTS, PAINT REMOVER, INSECTICIDES,
WEED KILLERS, CONTAIN HARMFUL VAPORS
AND POISONS.
HOW TO PREVENT IT
NEVER OPERATE THE COMPRESSOR
OUTDOORS WHEN IT IS RAINING OR IN WET
CONDITIONS.
NEVER OPERATE COMPRESSOR WITH
PROTECTIVE COVERS REMOVED OR
DAMAGED.
ANY ELECTRICAL WIRING OR REPAIRS
REQUIRED ON THIS PRODUCT SHOULD BE
PERFORMED BY AUTHORIZED SERVICE
CENTER PERSONNEL IN ACCORDANCE WITH
NATIONAL AND LOCAL ELECTRICAL CODES.
MAKE CERTAIN THAT THE ELECTRICAL
CIRCUIT TO WHICH THE COMPRESSOR IS
CONNECTED PROVIDES PROPER
ELECTRICAL GROUNDING, CORRECT
VOLTAGE AND ADEQUATE FUSE
PROTECTION.
HOW TO PREVENT IT
AIR OBTAINED DIRECTLY FROM THE
COMPRESSOR SHOULD NEVER BE USED TO
SUPPLY AIR FOR HUMAN CONSUMPTION. IN
ORDER TO USE AIR PRODUCED BY THIS
COMPRESSOR FOR BREATHING, SUITABLE
FILTERS AND IN-LINE SAFETY EQUIPMENT
MUST BE PROPERLY INSTALLED. IN-LINE
FILTERS AND SAFETY EQUIPMENT USED IN
CONJUNCTION WITH THE COMPRESSOR
MUST BE CAPABLE OF TREATING AIR TO ALL
APPLICABLE LOCAL AND FEDERAL CODES
PRIOR TO HUMAN CONSUMPTION.
WORK IN AN AREA WITH GOOD CROSSVENTILATION. READ AND FOLLOW THE
SAFETY INSTRUCTIONS PROVIDED ON THE
LABEL OR SAFETY DATA SHEETS FOR THE
MATERIAL YOU ARE SPRAYING. USE A
NIOSH/MSHA APPROVED RESPIRATOR
DESIGNED FOR USE WITH YOUR SPECIFIC
APPLICATION.
5- ENG
D24225
HAZARD
RISK OF BURNS
WHAT CAN HAPPEN
TOUCHING EXPOSED METAL SUCH AS THE
COMPRESSOR HEAD OR OUTLET TUBES,
CAN RESULT IN SERIOUS BURNS.
HAZARD
RISK FROM MOVING PARTS
WHAT CAN HAPPEN
MOVING PARTS SUCH AS THE PULLEY,
FLYWHEEL AND BELT CAN CAUSE SERIOUS
INJURY IF THEY COME INTO CONTACT WITH
YOU OR YOUR CLOTHING.
ATTEMPTING TO OPERATE COMPRESSOR
WITH DAMAGED OR MISSING PARTS OR
ATTEMPTING TO REPAIR COMPRESSOR
WITH PROTECTIVE SHROUDS REMOVED CAN
EXPOSE YOU TO MOVING PARTS AND CAN
RESULT IN SERIOUS INJURY.
HAZARD
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.
HOW TO PREVENT IT
NEVER TOUCH ANY EXPOSED METAL PARTS
ON COMPRESSOR DURING OR IMMEDIATELY
AFTER OPERATION. COMPRESSOR WILL
REMAIN HOT FOR SEVERAL MINUTES AFTER
OPERATION.
DO NOT REACH AROUND PROTECTIVE
SHROUDS OR ATTEMPT MAINTENANCE
UNTIL UNIT HAS BEEN ALLOWED TO COOL.
HOW TO PREVENT IT
NEVER OPERATE THE COMPRESSOR WITH
GUARDS OR COVERS WHICH ARE DAMAGED
OR REMOVED.
ANY REPAIRS REQUIRED ON THIS PRODUCT
SHOULD BE PERFORMED BY AUTHORIZED
SERVICE CENTER PERSONNEL.
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.
HAZARD
RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR
(Fire, Inhalation, Damage to Vehicle Surfaces)
WHAT CAN HAPPEN
OIL CAN LEAK OR SPILL AND COULD
RESULT IN FIRE OR BREATHING HAZARD,
SERIOUS INJURY OR DEATH CAN RESULT.
OIL LEAKS WILL DAMAGE CARPET, PAINT OR
OTHER SURFACES IN VEHICLES OR
TRAILERS.
D24225
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.
6- ENG
HOW TO PREVENT IT
SPECIFICATIONS
Model No. CPLMC7580V2C
Horsepower 7.5
Voltage/Hertz/Phase 240/60/1
Minimum Branch Circuit Requirement 30 Amp
*Fuse Type Time Delay
Air Tank Capacity (Gallon) 80 ASME, Vertical
Approximate Cut-in Pressure 145 PSIG
Approximate Cut-out Pressure 175 PSIG
SCFM @ 175 PSIG 23.5
Magnetic Starter Included
* A circuit breaker is preferred. Use only a fuse or circuit breaker that is the same
rating as the branch circuit on which the air compressor is operated. If
compressor is connected to a circuit protected by fuses, use only time delay
fuses. Time delay fuses should be marked "D" in Canada and "T" in the US.
GLOSSARY
Become familiar with these terms before operating the unit.
CFM: Cubic feet per minute.
SCFM: Standard cubic feet per minute; a unit of measure of air delivery.
PSIG: Pounds per square inch gauge; a unit of measure of pressure.
Code Certification: Products that bear one or more of the following marks:
UL, CUL, ETL, CETL, have been evaluated by OSHA certified independent
safety laboratories and meet the applicable Underwriters Laboratories
Standards for Safety.
Cut-In Pressure: While the motor is off, air tank pressure drops as you
continue to use your accessory. When the tank pressure drops to a certain low
level the motor will restart automatically. The low pressure at which the motor
automatically restarts is called "cut-in" pressure.
Cut-Out Pressure: When an air compressor is turned on and begins to run,
air pressure in the air tank begins to build. It builds to a certain high pressure
before the motor automatically shuts off - protecting your air tank from
pressure higher than its capacity. The high pressure at which the motor shuts
off is called "cut-out" pressure.
Branch Circuit: Circuit carrying electricity from electrical panel to outlet.
DUTY CYCLE
Air compressors should be operated on 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.
ACCESSORIES
Accessories for this unit are available at the store the unit was purchased.
7- ENG
D24225
ASSEMBLY
Tools Required for Assembly
1 - 9/16" socket or open end wrench
1 - electric drill
Unpacking
1. Remove all packaging.
It may be necessary to brace or support one side of the
compressor will have a tendency to tip.
2. Remove and discard the (4) screws and washers holding the compressor
to the pallet.
3. With the help of another person carefully remove air compressor from
pallet and place on a level surface.
To Add Oil To Pump
air compressor. This is due to plant testing and does not mean the pump
contains oil. Do not attempt to operate this air compressor without first
adding oil to the crankcase. Serious damage can result from even limited
operation unless filled with oil and broken in correctly. Make sure to
closely follow initial start-up procedures.
used in an air compressor. They leave carbon
deposits on critical components, thus reducing
performance and compressor life. Use air
compressor oil only.
NOTE: Use an air compressor oil such as SAE-30
(API CG/CD heavy duty motor oil). Under extreme
winter conditions use SAE-20 weight oil.
1. Place unit on a level surface.
2. Remove oil fill plug (A) and slowly add
compressor oil until the oil level is in the middle
of the sightglass (B). NOTE: When filling the
crankcase, the oil flows very slowly into the
pump. If the oil is added too quickly, it will
overflow and appear to be full. NOTE:
Crankcase oil capacity is approximately 40
fluid ounces.
3. Replace oil fill plug.
outfit when removing the pallet because the air
Compressors are shipped without oil. A small amount
of oil may be present in the pump upon receipt of the
Multi-Viscosity motor oils,
like 10W 30, should not be
A
B
D24225
8- ENG
To Install Air Filter
Attach elbow to pump using bolts provided. Tighten until
snug. Insert threaded end of air filter assembly into elbow
and tighten until snug.
INSTALLATION
HOW TO SET UP YOUR UNIT
Location of the Air Compressor
• Locate the air compressor in a clean, dry, and well ventilated area.
• Located the air compressor at least 12" away from the wall or other
obstructions that will interfere with the flow of air.
• Locate the air compressor as close to the main power supply as possible
to avoid using long lengths of electrical wiring. NOTE: Long lengths of
electrical wiring could cause power loss to the motor.
• The air filter must be kept clear of obstructions which could reduce air flow
to the air compressor.
Anchoring of the Air Compressor
Excessive Vibration can weaken the air tank and cause an
explosion. The compressor must be properly mounted.
The air compressor MUST be bolted to a solid, level surface.
Hardware needed:
4 - Concrete anchors (not supplied)
4 - 3/8" Lag screw to fit concrete anchors (not supplied)
4 - 5/8" Washer (supplied)
- Shims (if needed)
1. Place the air compressor on on a solid, level surface.
2. Mark the surface using the holes in the air compressor feet as a template.
3. Drill holes in the surface for the concrete anchors. Install concrete anchors.
4. Line-up holes in surface with holes in air compressor feet.
3/8" Lag
Screw
(not supplied)
5/8" Washer
(supplied)
Shim Under
Washer
(not supplied)
9- ENG
Surface Line
Concrete Anchor
(not supplied)
D24225
5. Place the (4) washers (supplied) between the floor and air compressor feet.
If needed, solid shims may be placed between the washers and floor to
evenly distribute weight on all four feet. See next figure.
6. Place the (4) 3/8" lag screws through the air compressor feet, washers,
shims, and into the anchors.
7. Torque 3/8" lag screws to 7-10 ft.-lbs.
Wiring Instructions
GROUNDING INSTRUCTIONS
This product should be connected to a metallic, permanent wiring system, of
an equipment-grounding terminal or lead on the product and comply with
national and local electrical codes.
Refer to the product specification found in the front of this manual for the
voltage and minimum branch circuit requirements.
RISK OF ELECTRICAL SHOCK. Improper electrical
grounding can result in electrical shock. The wiring
should be done by a qualified electrician to comply with national and local
electrical codes.
A qualified electrician needs to knows the following before wiring:
1. The amperage rating of the electrical box should be adequate. Refer to the
product specifications, found in the front of this manual, for this
information.
2. The supply line should have the same electrical characteristics (voltage,
cycle, phase) as the motor. Refer to the motor nameplate, on side of
motor, for this information.
NOTE: The wiring must be the same as the motor nameplate voltage plus or
minus 10%. Refer to local codes for recommended wire sizes, correct wire
size, and maximum wire run; undersize wire causes high amp draw and
overheating to the motor.
3. The wiring diagram for the magnetic starter box (if equipped) can be found
inside the magnetic starter box cover.
Electrical wiring must be located away from hot surfaces
such as manifold assembly, compressor outlet tubes,
heads, or cylinders.
Air Distribution System
Plastic or PVC pipe is not designed for use with
compressed air. Regardless of its indicated pressure
rating, plastic pipe can burst from air pressure. Use only metal pipe for air
distribution lines.
The next figure represents a typical air distribution system. The following are
tips to remember when setting up the air compressor’s air distribution system.
D24225
10- ENG
● Use pipe that is the same size as the air tank outlet. Piping that is too
small will restrict the flow of air.
● If piping is over 100 feet long, use the next larger size.
● Bury underground lines below the frost line and avoid pockets where
condensation can gather and freeze. Apply pressure before underground
lines are covered to make sure all pipe joints are free of leaks.
● A flexible coupling is recommended to be installed between the air
discharge outlet and main air distribution line to allow for vibration.
● A separate regulator is recommended to control the air pressure. Air
pressure from the tank is usually to high for individual air driven tools.
AIR FLOW
MAIN DISTRIBUTION AIR LINES
Slope pipe in direction of air flow.
Water condensate flows along
bottom of pipe to drain legs,
preventing it from entering feeder
lines.
LUBRICATOR
MOISTURE
SEPARATOR
AND TRAP
DIRT
LEG
FEEDER LINES SLOPE
WITH AIR FLOW
REGULATOR
DRAIN
TRAP
AIR USAGE
LINES
DIRT
LEG
AIR FLOW
FILTER
FLEXIBLE
COUPLING
AIR DISCHARGE
VALVE
DRAIN
LEGS
DRAIN
TRAPS
REGULATOR
COMPRESSOR
LUBRICATOR
AIR
TYPICAL COMPRESSED
AIR DISTRIBUTION SYSTEM
11- ENG
DRAIN COCK
VALVE
D24225
OPERATION
Know Your Air Compressor
READ THIS OWNER’S MANUAL AND SAFETY RULES BEFORE OPERATING
YOUR UNIT. Compare the illustrations with your unit to familiarize yourself with
the location of various controls and adjustments. Save this manual for future
reference.
Description of Operation
Become familiar with these controls before operating the unit.
On/Auto/Off Switch: Turn this switch
ON to provide automatic power to
the pressure switch and OFF to
remove power at the end of each
On/Auto/Off
Switch
use.
Pressure Switch: The pressure
switch automatically starts the motor
when the air tank pressure drops
below the factory set "cut-in"
pressure. It stops the motor when the
air tank pressure reaches the factory
set "cut-out" pressure.
Safety Valve: If the pressure switch
does not shut off the air compressor
Safety Valve
at its "cut-out" pressure setting, the
safety valve will protect against high
pressure by "popping out" at its factory set pressure (slightly higher than the
pressure switch "cut-out" setting).
Tank Pressure Gauge: The tank pressure gauge indicates the reserve air
pressure in the tank.
Globe Valve: Opens and closes air discharge valve. Turn knob counterclockwise to open and clockwise to close.
Drain Valve: The drain valve is located at the
base of the air tank and is used to drain
condensation at the end of each use.
Cooling System (not shown): This compressor
contains an advanced design cooling system. At
Drain
Valve
the heart of this cooling system is an engineered
fan. It is perfectly normal for this fan to blow air through the vent holes in large
amounts. You know that the cooling system is working when air is being
expelled.
Air Compressor Pump (not shown): Compresses air into the air tank.
Working air is not available until the compressor has raised the air tank
pressure above that required at the air outlet.
Pressure
Switch
Tank
Pressure
Gauge
Globe Valve
D24225
12- ENG
Check Valve: When the air compressor is operating,
the check valve is "open", allowing compressed air to
enter the air tank. When the air compressor reaches
"cut-out" pressure, the check valve "closes", allowing
air pressure to remain inside the air tank.
Pressure Release Valve: The pressure release valve,
located on the side of the pressure switch, is
designed to automatically release compressed air
from the compressor head and the outlet tube when
the air compressor reaches "cut-out" pressure or is
shut off. The pressure release valve allows the motor
to restart freely. When the motor stops running, air
will be heard escaping from this valve for a few
seconds. No air should be heard leaking when the
motor is running, or continuous leaking after unit
reaches "cut-out" pressure.
Air Intake Filter (not shown) This filter is designed to clean air coming into
the pump. This filter must always be clean and ventilation openings free from
obstructions. See "Maintenance".
Check Valve
Pressure
Release
Valve
How to Use Your Unit
How to Stop:
1. Set the On/Auto/Off lever to "OFF".
Before Starting
Break-in Procedure
Serious damage may result if the following break-in
instructions are not closely followed.
This procedure is required before the air compressor is put into service and
when the check valve or a complete compressor pump has been replaced.
1. Make sure the On/Auto/Off lever is in the "OFF" position.
2.
Recheck all wiring. Make sure wires are secure at all terminals connections.
Make sure all contacts move freely and are not obstructed.
3. Open the globe valve fully to permit air to escape and prevent air pressure
build up in the air tank during the break-in period.
4. Move the On/Auto/Off lever to "ON/AUTO" position. The compressor will
start.
5. Run the compressor for 20 minutes. Make sure the globe valve is open
and there is minimal air pressure build-up in tank.
6. Check all air line fittings and connections/piping for air leaks by applying a
soap solution. Correct if necessary. NOTE: Minor leaks can cause the air
compressor to overwork, resulting in premature breakdown or inadequate
performance.
13- ENG
D24225
7. Check for excessive vibration. Readjust or shim air compressor feet, if
necessary.
8. After 20 minutes, close the globe valve.The air receiver will fill to "cut-out"
pressure and the motor will stop.
Before Each Start-Up:
1. Place On/Auto/Off lever to "OFF".
2. Close the globe valve.
3. Attach hose and accessories. NOTE: A regulator MUST be installed when
using accessories rated at less than 175 PSI.
Too much air pressure causes a hazardous risk of
rating for air tools and accessories. The regulator outlet pressure must
never exceed the maximum pressure rating.
bursting. Check the manufacturer’s maximum pressure
How to Start
1. Turn the On/Auto/Off lever to "AUTO" and allow tank pressure to build.
Motor will stop when tank pressure reaches "cut-out" pressure.
2. When the tank pressure reaches "cut-out" pressure open the globe valve.
IMPORTANT: When using regulator and other accessories refer to the
manufacturer-s instructions.
NOTE: Always operate the air compressor in well-ventilated areas free of
gasoline or other combustible vapors. If the compressor is being used to
operate a sprayer, DO NOT place compressor near the spray area.
D24225
14- ENG
MAINTENANCE
Customer Responsibilities
Before
each
use
Check Safety Valve
●
Drain Tank
Check Oil
Change Oil
Unusual Noise and/or
Vibration
Air Filter
Drive Belt-Condition
Motor Pulley/Flywheel alignment
Air compressor pump intake
and exhaust valves
Inspect air lines and fittings
for leaks
●
Head Bolts - Check the torques of the head bolts after the first five hours of operation.
1- more frequent in dusty or humid conditions
2- more frequent if humidity or operating conditions are extreme.
Unit cycles automatically when power is on. When
performing maintenance, you may be exposed to voltage
sources, compressed air, or moving parts. Personal injuries can occur.
Before performing any maintenance or repair, disconnect power source
from the compressor and bleed off all air pressure.
To ensure efficient operation and longer life of the air compressor outfit, a
routine maintenance schedule should be prepared and followed. The following
routine maintenance schedule is geared to an outfit in a normal working
environment operating on a daily basis. If necessary, the schedule should be
modified to suit the conditions under which your compressor is used. The
modifications will depend upon the hours of operation and the working
environment. Compressor outfits in an extremely dirty and/or hostile
environment will require a greater frequency of all maintenance checks.
Every
8
hours
●
●
●
Every
40
hours
●
●
Every
Every
100
160
hours
hours
2
●
1
Every
500
hours
2
●
Yearly
●
●
NOTE: See "Operation" section for the location of controls.
To Check Safety Valve
If the safety valve does not work properly, overpressurization may occur, causing air tank rupture or an
explosion.
1. Before starting compressor, pull the ring on the safety valve to make sure
that the safety valve operates freely. If the valve is stuck or does not
operate smoothly, it must be replaced with the same type of valve.
15- ENG
D24225
To Drain Tank
NOTE: Operation of the air compressor will cause condensation to build up in
the air tank. Always drain tank on a washable surface or in a suitable container
to prevent damaging or staining surfaces.
1. Set the On/Auto/Off lever to "OFF".
2. Close the globe valve.
3. Remove the air tool or accessory.
4. Open the globe valve and allow the air to slowly bleed from the air tank
until tank pressure is approximately 20 psi.
5. Close the globe valve.
6. Drain water from air tank by opening drain valve (counter-clockwise) on
bottom of tank.
Water will condense in the air tank. If not drained, water
will corrode and weaken the air tank causing a risk of air
tank rupture.
7. After the water has been drained, close the drain valve (clockwise). The air
compressor can now be stored.
NOTE: If drain valve is plugged, release all air pressure. The valve can then be
removed, cleaned, then reinstalled.
Oil
Checking
1. The oil level should be to the middle of the
sight glass (C).
2. If needed remove oil fill plug (A) and slowly add
oil until it reaches the middle of the sight glass.
NOTE: Use a air compressor oil such as SAE-30
(API CG/CD heavy duty motor oil). Under extreme
winter conditions use SAE-20 weight oil.
Changing
1. Remove the oil fill plug (A).
2. Remove the oil drain plug (B) and drain oil into
a suitable container.
3. Replace the oil drain plug (B) and tighten
securely
NOTE: Use a air compressor oil such as SAE-30
(API CG/CD heavy duty motor oil). Under extreme
winter conditions use SAE-20 weight oil.
4. Slowly add compressor oil until the oil level is
in the middle of the sightglass (B). NOTE:
When filling the crankcase, the oil flows very
slowly into the pump. If the oil is added too
quickly, it will overflow and appear to be full.
NOTE: Crankcase oil capacity is approximately
40 fluid ounces (1.2 L).
Overfilling with oil will cause
premature compressor failure.
Do not overfill.
5. Replace oil fill plug (A) and tighten securely.
C
B
A
D24225
16- ENG
Air Filter - Inspection and Replacement
Hot surfaces. Risk of burn. Compressor heads are
exposed when filter cover is removed. Allow compressor
to cool prior to servicing.
A dirty air filter will not allow the compressor to operate at full capacity. Keep
the air filter clean at all times.
1. Remove the air filter cover.
2. Remove the air filter from filter cover.
IMPORTANT: Do not operate the compressor with the air filter removed.
3. Place new air filter into filter cover. Refer to the "Repair Parts" for the
correct part number.
4. Replace air filter cover and lock into place.
Belt - Replacement
(Refer to the Outfit Parts Manual for replacement belt part number.)
Serious injury or damage may occur if parts of the body or
outfit with the belt guard removed. The belt guard should be removed only
when the AIR compressor power is disconnected.
1. Turn air compressor off, lock out the power supply, and relieve all air
pressure from the air tank.
2. Remove the belt guard.
3. Mark pump position on saddle.
4. Loosen the motor mounting screws and slide the motor toward the air
compressor.
5. Remove the belt and replace with a new one.
6. See the "Adjust Belt Tension" before tightening motor mounting screws.
loose items get caught in moving parts. Never operate the
Adjusting Belt Tension
1. Slide motor into original position, line the motor up with the mark made
earlier on saddle.
2. Tighten two outside motor mounting screws enough to hold the motor in
place for checking pulley and
flywheel alignment.
3. The belt should deflect 3/16" at
midway between the pulley and
the flywheel when a 5 pound
weight is applied at the midway
point.
3. When proper belt tension is
achieved, tighten all four motor
mounting screws. See Parts
manual for torque specifications.
NOTE: Once the engine pulley has been moved from its factory set location,
the grooves of the flywheel and pulley must be aligned to within 1/16" to
prevent excessive belt wear. Verify the alignment by performing the following
Pulley and Flywheel - Alignment.
17- ENG
Downward Force
Deflection
D24225
Motor Pulley/Flywheel Alignment
NOTE: Once the motor pulley has been moved from its factory set location,
the grooves of the flywheel and pulley must be aligned to within 1/16" to
prevent excessive belt wear.
The air compressor flywheel and motor pulley must be in-line (in the same
plane) within 1/16" to assure belt retention within flywheel belt grooves. To
check alignment, perform the following steps:
1. Turn air compressor off, lock out the power supply, and relieve all air
pressure from the air tank.
2. Remove belt guard
3. Place a straightedge against the
outside of the flywheel and the
motor drive pulley.
4. Measure the distance between
the edge of the belt and the
straightedge at points A1 and A2
in figure. The difference
between measurements should be no more than 1/16".
5. If the difference is greater or less than 1/16" loosen the set screw holding
the motor drive pulley to the shaft and adjust the pulley’s position on the
shaft until the A1 and A2 measurements are within 1/16" of each other.
6. Tighten the motor drive pulley set screw. See Parts manual for torque
specifications.
7. Visually inspect the motor drive pulley to verify that it is perpendicular to
the drive motor shaft. Points B1 and B2 of Figure should appear to be
equal. If they are not, loosen the setscrew of the motor drive pulley and
equalize B1 and B2, using care not to disturb the belt alignment performed
in step 2.
8. Retighten the motor drive pulley setscrew. See Parts manual for torque
specifications.
9. Reinstall belt guard.
Air Compressor Pump Intake and Exhaust Valves
Once a year have a Trained Service Technician check the air compressor pump
intake and exhaust valves.
Inspect Air Lines and Fittings for Leaks
1. Turn air compressor off, lock out the power supply, and relieve all air
pressure from the air tank.
2. Apply a soap solution to all air line fittings and connections/piping.
3. Correct any leaks found.
IMPORTANT: Even minor leaks can cause the air compressor to overwork,
resulting in premature breakdown or inadequate performance.
Air compressor Head Bolts - Torquing
The air compressor pump head bolts should be kept properly torqued. Check
the torques of the head bolts after the first five hours of operation. Retighten if
necessary. See Parts manual for torque specifications.
D24225
18- ENG
SERVICE AND ADJUSTMENTS
Unit cycles automatically when power is on. When doing
Maintenance, you may be exposed to voltage sources,
compressed air or moving parts. Personal injuries can occur. Before
performing any Maintenance or repair, unplug the compressor and bleed
off all air pressure.
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE
PERFORMED BY TRAINED SERVICE TECHNICIAN.
●
Unplug or disconnect electrical supply to the air compressor.
●
Bleed tank of pressure.
●
Allow the air compressor to cool.
Before servicing:
To Replace or Clean Check Valve
1. Release all air pressure from air tank. See "To Drain Tank" in the
Maintenance section.
2. Turn air compressor off, lock out the power supply, and relieve all air
pressure from the air tank.
3. Using an adjustable wrench loosen outlet tube nut at air tank and pump.
Carefully move outlet tube away from check valve.
Pressure
Relief Tube
Check
Valve
Outlet Tube
4. Using an adjustable wrench loosen pressure relief tube nut at air tank and
pressure switch. Carefully move pressure relief tube away from check
valve.
5. Unscrew the check valve (turn counterclockwise) using a 7/8" open end
wrench. Note the orientation for reassembly.
19- ENG
D24225
6. Using a screwdriver, carefully push the valve disc up and down. NOTE:
The valve disc should move freely up and down on a spring which holds
the valve disc in the closed position, if not the check valve needs to be
cleaned or replaced.
Screwdriver
In closed position
disc is visible.
In open position
nothing is visible.
7. Clean or replace the check valve. A solvent, such as paint or varnish
remover can be used to clean the check valve.
8. Apply sealant to the check valve threads. Reinstall the check valve (turn
clockwise).
9. Replace the pressure release tube. Tighten nuts.
10. Replace the outlet tube and tighten nuts.
11. Perform the Break-in Procedure. See "Break-in Procedure" in the
Operation section.
Motor
This motor has a manual thermal overload protector.
If the motor overheats for any reason, the overload
protector will shut off the motor. The motor must be
allowed to cool down before restarting. To restart:
1. Place the On/Auto/Off lever in the Off position.
2. Allow the motor to cool.
3. Depress the red reset button on the motor.
4. Place the On/Auto/Off lever in the On/Auto postion to restart the motor.
IMPORTANT: If the overload protector shuts the motor off frequently, check for
a possible voltage problem. Low voltage can also be suspected when:
1. The motor does not get up to full power or speed.
2. Fuses blow out when starting the motor; lights dim and remain dim when
motor is started and is running.
Additional Service
Disassembly or service of the air compressor beyond what is covered in this
manual is not recommended. If additional service is required, contact your
nearest Authorized Warranty Service Center.
D24225
20- ENG
STORAGE
Before you store the air compressor, make sure you do the following:
1. Review the "Maintenance" section on the preceding pages and perform
scheduled maintenance as necessary.
2. Set the On/Auto/Off lever to "OFF".
3. Close the globe valve.
4. Remove the air tool or accessory.
5. Open the globe valve and allow the air to slowly bleed from the air tank
until tank pressure is approximately 20 psi.
6. Drain water from air tank by opening drain valve (counter-clockwise) on
bottom of tank.
Water will condense in the air tank. If not drained, water
will corrode and weaken the air tank causing a risk of air
tank rupture.
7. After the water has been drained, close the drain valve.
NOTE: If drain valve is plugged, release all air pressure. The valve can then be
removed, cleaned, then reinstalled.
8. Protect the air hose from damage (such as being stepped on or run over).
21- ENG
D24225
TROUBLESHOOTING
Performing repairs may expose voltage sources, moving
compressd air sources. Personal injury may occur. Prior to attempting any
repairs, unplug the air compressor and bleed off all air tank air pressure.
parts or compressed air sources, moving parts or
PROBLEM
Excessive tank
pressure safety valve
pops off.
Air leaks at
fittings.
Air leaks at or
inside check
valve.
Air leaks at
pressure switch
release valve.
(if equipped)
Air leaks in air
tank or at air
tank welds.
CAUSE
Pressure switch does not
shut off motor when
compressor reaches "cutout" pressure.
Pressure switch "cut-out"
too high.
Tube fittings are not tight
enough.
Check valve seat damaged.
Defective pressure switch
release valve.
Defective air tank.
CORRECTION
Move On/Auto/Off lever to
the "OFF" position, if the
outfit does not shut off
contact a Trained Service
Technician.
Contact a Trained Service
Technician.
Tighten fittings where air can
be heard escaping. Check
fittings with soapy water
solution. DO NOT
OVERTIGHTEN.
A defective check valve
results in a constant air leak
at the pressure release valve
when there is pressure in the
tank and the compressor is
shut off. Replace check
valve. Refer the "To Replace
or Clean Check Valve" in the
"Service and Adjustments"
section.
Contact a Trained Service
Technician.
Air tank must be replaced.
Do not repair the leak.
Do not
drill into,
weld or otherwise modify
air tank or it will weaken.
The tank can rupture or
explode.
Air leaks
between head
and valve plate.
D24225
Leaking seal.
Contact a Trained Service
Technician.
22- ENG
PROBLEM
Pressure reading
on the regulated
pressure gauge
(if equipped)
drops when an
accessory is
used.
CAUSE
It is normal for "some"
pressure drop to occur.
CORRECTION
If there is an excessive amount
of pressure drop when the
accessory is used, adjust the
regulator as instructed in the
Operation section.
NOTE: Adjust the regulated
pressure under flow conditions
(while accesory is being used).
Air leak from
safety valve.
Compressor is
not supplying
enough air to
operate
accessories.
Restricted air
intake.
Possible defect in safety
valve.
Prolonged excessive use of
air.
Compressor is not large
enough for air requirement.
Hole in hose.
Check valve restricted.
Air leaks.
Restricted air intake filter
Loose belt.
Dirty air filter.
Operate safety valve manually
by pulling on ring. If valve still
leaks, it should be replaced.
Decrease amount of air usage.
Check the accessory air
requirement. If it is higher than
the SCFM or pressure supplied
by your air compressor, you
need a larger compressor.
Check and replace if required.
Remove and clean, or replace.
Tighten fittings.
Clean or replace air intake
filter. Do not operate the air
compressor with the filter
removed. Refer to the "Air
Filter" paragraph in the
"Maintenance " section.
Check belt tension, see
Adjusting Belt Tension in the
Maintenance section.
Clean or replace. See Air Filter
paragraph in the Maintenance
section.
Safety Valve on
pump "pops"
out.
Pressure switch, check
valve, or pump could be
in need of servicing.
23- ENG
Have checked by a Trained
Service Technician.
D24225
PROBLEM
Motor will not
run.
CAUSE
Motor overload protection
switch has tripped.
CORRECTION
Let motor cool off and
overload switch will
automatically reset.
Tank pressure exceeds
pressure switch "cut-in"
pressure.
Check valve stuck open.
Loose electrical
connections.
Possible defective motor
or starting capacitor.
Paint spray on internal
motor parts.
Pressure release valve on
pressure switch has not
unloaded head pressure.
Fuse blown, circuit breaker
tripped.
Motor will start automatically
when tank pressure drops
below "cut-in" pressure of
pressure switch.
Remove and clean, or replace.
Check wiring connection
inside pressure switch and
terminal box area.
Have checked by a Trained
Service Technician.
Have checked by a Trained
Service Technician. Do not
operate the compressor in the
paint spray area. See
flammable vapor warning.
Bleed the line by pushing the
lever on the pressure switch to
the "off" position; if the valve
does not open, replace switch.
1. Check fuse box for blown
fuse and replace as
necessary. Reset circuit
breaker. Do not use a fuse
or circuit breaker with
higher rating than that
specified for your
particular branch circuit.
2. Check for proper fuse. You
should use a time delay
fuse.
3. Check for low voltage
conditions and/or proper
extension cord.
4. Disconnect the other
electrical appliances from
circuit or operate the
compressor on its own
branch circuit.
D24225
24- ENG
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