Rockford Fosgate CAT1040 Operations & Parts Manual
OPERATION & PARTS MANUAL
MODEL NO.: CAT1040
10 GALLON AIR COMPRESSOR
BEFORE USING THIS PRODUCT.
WARNING: READ THIS MANUAL FOR ALL SAFETY INSTRUCTIONS
SPECIFICATIONS:
Compressor ……………………… Oil lubricated
Horsepower…………………………3.0HP
Input …………………………………120V/60Hz, 15Amps
Tank Capacity ………………………10 Gallons
Air Pressure …………………………125psi max.
Speed ………………………………. 3400 RPM
Air Delivery ………………………… 5.1 SCFM @40PSI
………………………… 4.1 SCFM @90PSI
Net Weight …………………………. 63.5 lbs
1
IMPORTANT SAFETY PRECAUTIONS
SAVE ALL INSTRUCTIONS Improper operation or maintenance of this product could
result in serious injury and/or property damage. Read and understand all of the warnings and safety
instructions provided before using this equipment.
Do not use this compressor to supply breathing air.
■
Risk of Moving Parts. If the air compressor is in operation, all guards and covers should be attached or installed
correctly. If any guard or cover has been damaged, do not operate the equipment until the proper personnel have
correctly repaired the equipment. The power cord should be free of any moving parts, twisting and/or crimping while in
use and while in storage.
■
Risk of Burns. There are surfaces on your air compressor that while in operation and thereafter can cause serious
burns if touched. The equipment should be allowed time to cool before any maintenance is attempted. Items such
as the compressor pump and the outlet tube are normally hot during and after operation.
■ Always Wear Approved Eye protection.
■ Risk of Falling. Operation of the air compressor should always be in a position that is stable. Never use the air
compressor on a rooftop or elevated position that could allow the unit to fall or be tipped over. Use additional air hose
for elevated jobs.
■
Risk from Flying Objects. Always wear approved safety glasses with side shields when the air compressor is in use.
Turn off the air compressor and drain the air tank before performing any type of maintenance or disassembly of the
hoses or fittings. Never point any nozzle or sprayer toward any part of the body or at other people or animals.
■
Risk to Breathing. Avoid using the air compressor in confined areas. Always have adequate space (30 cm) on all
sides of the air compressor. Also keep children, pets, and others out of the area of operation. This air compressor does
not provide breathable air for anyone or any auxiliary breathing device. Spraying material will always need to be in
another area away from the air compressor to not allow intake air to damage the air compressor filter.
■
Risk of Electrical Shock. Never utilize the air compressor in the rain or wet conditions. Any electrical issues or
repairs should be performed by authorized personnel such as an electrician and should comply with all national and
local electrical codes. The air compressor should also have the proper three prong grounding plug, correct voltage, and
adequate fuse protection.
■
Risk of Explosion or Fire. Never operate the compressor near combustible materials, gasoline or solvent vapors. If
spraying flammable materials, locate the air compressor at least 50m away from the spray area. Never operate the air
compressor indoors or in a confined area.
■
Risk of Bursting. Always drain the air compressor tank daily or after each use. If the tank develops a leak, then
replace the air compressor. Never use the air compressor after a leak has been found or tried to make any
modifications to the tank. Never modify the air compressor's factory settings which control the tank pressure or any
other function.
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.
CALIFORNIA PROPOSITION 65 This product or its power cord may contain chemicals,
including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. Wash
hands after handling.
SOME DUST CREATED BY POWER SANDING, SAWING, GRINDING, DRILLING, AND
OTHER CONSTUCTION ACTIVITIES CONTAINS CHEMICALS KNOWN TO CAUSE CANCER, BIRTH DEFECTS OR
REPRODUCTIVE HARM.
2
PARTS & FEATURES
Drain Valve: Used to drain condensation from the air tank. Located at bottom of tank.
Tank Safety Valve: Used to allow excess tank pressure to escape into the atmosphere. This valve should only open
when the tank pressure is above the maximum rated pressure.
Tank Pressure Gauge: Indicates the reserve air pressure in the tank.
Outlet Pressure Gauge: Indicates the outgoing air pressure to the tool and is controlled by the regulator.
Regulator: The regulator controls the air pressure coming from the air tank. To increase the pressure, turn the knob
clockwise and to decrease the pressure turn the knob counterclockwise.
Quick Coupler: Offers a quick release feature for attaching and removing the air hose.
Motor Thermal Overload: The motor has an automatic thermal overload protector. If the motor overheats, this
protector will shut off the motor. The motor must be allowed 30 minutes to cool before restarting.
Auto/Off Switch: In the AUTO position, the compressor shuts off automatically when tank pressure reaches the
maximum preset pressure. In the OFF position, the compressor will not operate. This switch should be in the OFF
position when connecting or disconnecting the power cord from the electrical outlet or when changing air tools.
INSTALLATION & ASSEMBLY
Handle. Align holes in Handle(#78) to holes in mounting plate with Cap Screws(#68), and secure with washers and
nuts.
Wheels. Attach Wheels(#72) to the tank with Axle Bolt(#73), with offset hub facing axle iron, and secure with
washers(#71) and nuts(#70).
Filter. Thread the Air Filter(#32) onto the Cylinder Head(#27).
Location of the Air Compressor. The air compressor should always be located in a clean, dry, and well-ventilated
environment. The unit should have at minimum, 30cm of space on each side. The air filter intake should be free of
any debris or obstructions. Check the air filter on a daily basis to be sure it is clean and in working order.
Extension Cords. Use only a 3-wire extension cord that has a 3-blade grounding plug, and a 3-slot receptacle that will
accept the plug on the product. Make sure your extension cord is in good condition. When using an extension cord, be
sure to use one heavy enough to carry the current your product will draw. Cords must not exceed 25 feet and No. 12
AWG size must be used. An undersized cord will cause a drop in line voltage resulting in loss of power and
overheating.
This product should be grounded. In the event of an electrical short
circuit, grounding reduces the risk of electric shock by providing an escape wire for the
electric current. This product is equipped with a cord having a grounding wire with an
appropriate grounding plug. The plug must be plugged into an outlet that is properly
installed and grounded in accordance with all local codes and ordinances.
This compressor is shipped without oil! FILL PROPER
OIL BEFORE OPERATING COMPRESSOR. Proper oil level is illustrated.
3
OPERATION PROCEDURES
Before First Start-up Procedures
1. Fill proper oil before operating compressor.
2. Turn regulator knob fully clockwise (to the right) to open air flow.
3. Turn on/off switch to OFF position.
4. Plug in power cord.
5. Turn on/off switch to AUTO position and run compressor for 30 minutes.
6. Turn on/off switch to OFF position.
7. Unplug power cord.
8. The compressor is now ready for use.
Daily Start-Up Procedures
1. Fill proper oil before operating compressor
2. Turn on/off switch to OFF position.
3. Check the air compressor visually for any damage or obstruction.
4. Close the drain valve.
5. Turn regulator knob fully counter clockwise (to the left) to close air flow.
6. Connect air hose to outlet of regulator.
7. Plug in power cord.
8. Turn on/off switch to AUTO position and let compressor run until it reaches automatic shutoff pressure.
9. Attach tire chuck or tool to end of hose.
10. Turn regulator knob clockwise (to the right) to desired pressure of tool being used.
11. The air compressor is now ready for use.
Improper installation of the grounding plug can result in a risk of electric shock. If repair or
replacement of the cord or plug is necessary, do not connect the grounding wire to either flat blade terminal. The wire
with insulation having an outer surface that is green with or without yellow stripes is the grounding wire. Check with a
qualified electrician or serviceman if the grounding instructions are not completely understood, or if in doubt as to
whether the product is properly grounded. Do not modify the plug provided; if it will not fit the outlet, have the proper
outlet installed by a qualified electrician.
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.
Never remove or attempt to adjust safety valve. Keep safety valve free from paint and other
accumulations.
Safety valve must be replaced if it cannot be actuated or it leaks air after ring is released.
Daily Shut-Down Procedures
1. Set the Auto-On/Off lever to the Off position.
2. Unplug the power cord from the receptacle.
3. Set the outlet pressure to zero on the regulator.
4. Remove any air tools or accessories.
5. Open the drain valve allowing air to bleed from the tank. After all of the air has bled from the tank, close the drain
valve to prevent debris buildup in the valve.
Water that remains in the tank during storage will corrode and weaken the air tank, which could cause the tank to
rupture. To avoid serious injury, be sure to drain the tank after each use or daily.
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Drain liquid from tank daily.
When draining the tank, always use ear and eye protection. Drain the tank in a suitable location;
condensation will be present in most cases of draining.
MAINTENANCE
NOTE: Qualified service personnel should perform any service procedure not covered in the maintenance schedule below.
ITEMS TO CHECK/CHANGE
Check Tank Safety Valve X
Overall Unit Visual Check
Check Air Filter (more frequently in dusty or humid environments)
To ensure efficient operation and longer life of the air compressor unit, a routine maintenance
schedule should be followed. The following schedule is geared toward a consumer whose compressor is used in a
normal working environment on a daily basis. If necessary, the schedule should be modified to suit the condition
under which your compressor is used. The modifications will depend upon the hours of operation and the working
environment. Air compressors used in an extremely dirty and/or hostile environment will require a greater frequency
of all maintenance checks.
Before Each
Use or Daily
X
X
After First Ten
Hours
Every 100
Hours
STORAGE
For storing the air compressor, be sure to do the following:
1. Turn the unit off and unplug the power cord from the receptacle.
2. Remove all air hoses, accessories, and air tools from the air compressor.
3. Perform the daily maintenance schedule.
4. Open the drain valve to bleed all air from the tank.
5. Close the drain valve.
6. Store the air compressor in a clean and dry location.
The air compressor should be turned off and unplugged from the power source before any
maintenance is performed as well as the air bled from the tank and the unit allowed time to cool. Personal injuries
could occur from moving parts, electrical sources, compressed air or hot surfaces.
TROUBLESHOOTING GUIDE
The air compressor should be turned off and unplugged from the power source before any maintenance is performed as well as
the air bled from the tank and the unit allowed time to cool. Personal injuries could occur from moving parts, electrical sources,
compressed air, or hot surfaces.
Problem Possible Cause & Corrective Action
Air leaks at the check valve o
at the pressure relief valve.
ir leaks between head and
cylinder.
when there is pressure in the tank and the compressor is shut off. Drain the tank,
then remove and clean or replace the check valve.
Be sure of proper torque on head bolts. If leak remains, contact a service
technician.
defective check valve results in a constant air leak at the pressure release valve
5
Air leak from safety valve. Operate the safety valve manually by pulling on the ring. If the valve continues to
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leak when in the closed position, it should be replaced.
Pressure reading on the
regulated pressure gauge
drops when an accessory is
used.
If there is an excessive amount of pressure drop when the accessory is used,
replace the regulator.
NOTE:
Adjust the regulated pressure under flow conditions (while accessory is being used).
It is normal for the gauge to show minimal pressure loss during initial use of the tool.
Excessive tank pressure. Move the Auto-On/Off lever to the Off position. If the unit doesn't shut off, unplug it
from the power source and contact a service technician.
Motor will not start. Make sure power cord is plugged in and the switch is on. Inspect for the proper size
fuse in your circuit box. If the fuse was tripped reset it and restart the unit. If repeated
tripping occurs, replace the check valve or contact your service technician.
Excessive moisture in the
discharge air.
Remove the water in the tank by draining after each use. High humidity
environments will cause excessive condensation. Utilize water filters on your air line.
NOTE:
Water condensation is not caused by compressor malfunction. Be sure the
compressor's air output is greater than your tool's air consumption rate.
ir leaks from the tank body
or tank welds.
Never drill into weld or otherwise modify the air tank or it will weaken. The tank can
rupture or explode. Compressor cannot be repaired. Discontinue use of the ai
compressor.
6
Exploded View and Parts List
7
Ref # Part Name
1 CRANK CASE
2 CRANK SHAFT
3 CONNECT ROD
4 BOLT
5* GASKET
6 CRANKCASE COVER
7* GASKET
8 OIL SIGHT GLASS
9 BOLT
10* BREATHER
11 CIRCLIP
12* PISTON PIN
13 PISON
14 PISTON RING
15 PISTON RING
16 GASKET
17 CYLINDER
18 ROUND PIN
19 VALVE SLICE
20* VALVE GASKET
21* VALVE
22* VALVE SLICE
23* VPRESSING GASKET
24* SPRING
25 BOLT
26* HEAD GASKET
27 CYLINDER HEAD
28 WASHER
29 SPRING
30 BOLT
31 ELBOW EXHAUST
32* AIR FILTER
33 COVER
34 WASHER
35 BOLT
36 CIRCLIP
37 FAN
38* BOLT
39* SPRING
40* WASHER
41 REAR BEARING CRANK
Mark (*) is easy-worn-out spare parts
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Ref # Part Name
42 STATOR
43 BEARING
44 ROTATOR
45 BEARING
46 OIL SEALING
47 CAPACITOR
48* NUT
49* BOLT
50* WASHER
51* BOLT
52* SPRING
53* NUT
54 PRESSURE SWITCH
55 CONNECTOR
56 TANK PRESSURE GAUGE
57 OUTPUT PRESSURE GAUGE
58 REGULATOR
59 QUICK COUPLER
60 SAFETY VALVE
61 CONNECTOR
62 UNLOADING NUT
63 UNLOADING TUBE
64 CHECK VALVE
65 EXHAUST NUT
66 EXHAUST TUBE
67 TANK
68 CAP SCREW
69 DRAIN VALVE
70 NUT
71 WASHER
72 WHEEL
73 AXLE BOLT
74 NUT
75 WASHER
76 CUSHION FOOT
77 BOLT
78 HANDLE
79 ELECTRICAL WIRE
80 PLUG
81 STARTER
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8
1 YEAR LIMITED WARRANTY
1. DURATION: From the date of purchase by the original purchaser.
2. WHO RECEIVES THIS WARRANTY(PURCHASER): The original purchaser(other than for purposes of resale)of
the Rockford air compressor.
3. WHAT PRODUCTS ARE COVERED UNDER THIS WARRANTY: Any Rockford air compressor supplied or
manufactured by the warrantor.
4．WHAT lS COVERED UNDER THIS WARRANTY: Substantial defects on material and workmanship which occur
within the duration of the warranty period with the exceptions noted below.
5. WHAT lS NOT COVERED UNDER THlS WARRANTY:
A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE
LIMITED FROM THE DATE OF ORIGINAL PURCHASE AS STATED IN THE DURATION. If this air compressor is
used for commercial, industrial or rental purposes．The warranty will apply for ninety(90) days from the date of
purchase. Some States do not allow limitation on how Iong an implied warranty Iasts. so the above limitations may
not apply to you.
B. ANY INCIDENTAL lNDIRECT OR CONSEQUENTIAL LOSS，DAMAGE，OR EXPENSE THAT MAY RESULT
FROM ANY DEFECT, FAlLURE, OR MALFUNCTION OF THE ROCKFORD AIR COMPRESSOR. Some States do
not allow the exclusion or limitation of incidental or consequential damages. so the above limitation or exclusion may
not apply to you.
C. Any failure that results from shipping damage, accident, purchaser’s abuse, neglect or failure to install and
operate air compressor in accordance with instructions provided in the owner's manual supplied with product.
D. Pre-delivery service, i.e. assembly, oil or lubricants and adjustment.
E. Items or service normally required to maintain the air compressor
F. Additional items not covered under the warranty:
1). Normal wear items such as quick coupler, plug, air chuck, Sealant tape, inflation needle, PVC hose，recoil
hose.
2). Cosmetic defects that do not interfere with functionality.
3). Rusted components.
4). Pump wear or valve damage caused by using improper oil, oil contamination or by failure to follow proper oil
maintenance guidelines.
6. RESPONSIBlLITlES OF WARRANTOR UNDER THlS WARRANTY: Repair or replace, at Warrantor’s option, air
compressor or component which is defective has malfunctioned and／or failed to conform within duration of the
warranty period.
7. RESPONSIBILITIES OF PURCHASER UNDER THlS WARRANTY:
A．Provide dated proof of purchase and maintenance records.
B．Deliver or ship the Rockford air compressor or components to Rockford Commercial warehouse. Inc. Freight
costs, if any must be borne by the purchaser.
C．Use reasonable care in the operation and maintenance of the air compressor as described in the owner’s
manual.
8. WHEN WARRANTOR WlLL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY: Repair or
replacement will be scheduled and serviced according to the normal work flow at the servicing Location, and
depending on the availability of replacement parts.
For customer service, call: 1-877-782-4111
Rockford Commercial Warehouse, Inc.
8105 Burden Road Machesney Park, IL 61115
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