Porter-Cable CPLKC7080V2 Instruction Manual

Air Compressor Instruction manual IMPORTANT Please make certain that the person who is to use this equipment carefully reads and understands these instructions before starting operations. Part No. D22944-049-2 ® ESPAÑOL: PÁGINA 27 FRANÇAIS: PAGE 53 To learn more about Porter-Cable visit our website at: http://www.porter-cable.com Copyright © 2004 Porter-Cable Corporation 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. CPLKC7080V2

Indicates an imminent- ly hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. Used without the safety alert symbol indicates a potentially hazardous situ- ation which, if not avoided, may result in property damage. 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 rec- ognize this information, we use the symbols below. Please read the manual and pay attention to these sections. IMPORTANT SAFETY INSTRUCTIONS Some dust created by power sanding, sawing, grinding, drilling, and other con- struction activities contains chemicals known (to the State of California) to 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 per- sonal injury. READ AND FOLLOW ALL INSTRUCTIONS. 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. Technical Service Manager Porter-Cable Corporation 4825 Highway 45 North P.O. Box 2468 Jackson, TN 38302-2468

SAVE THESE INSTRUCTIONS IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL WARN- INGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT. RISK OF EXPLOSION OR FIRE ALWAYS OPERATE THE COMPRESSOR IN A WELL VENTILATED AREA FREE OF COM- BUSTIBLE MATERIALS, GASOLINE OR SOL- VENT 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 COMPRES- SOR. NEVER PLACE OBJECTS AGAINST OR ON TOP OF COMPRESSOR. OPERATE COM- PRESSOR 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. HOW TO PREVENT IT IT IS NORMAL FOR ELECTRICAL CONTACTS WITHIN THE MOTOR AND PRESSURE SWITCH TO SPARK. IF ELECTRICAL SPARKS FROM COMPRES- SOR COME INTO CONTACT WITH FLAMMA- BLE VAPORS, THEY MAY IGNITE, CAUSING FIRE OR EXPLOSION. RESTRICTING ANY OF THE COMPRESSOR VENTILATION OPENINGS WILL CAUSE SERI- OUS OVERHEATING AND COULD CAUSE FIRE. UNATTENDED OPERATION OF THIS PROD- UCT COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE. TO REDUCE THE RISK OF FIRE, DO NOT ALLOW THE COM- PRESSOR TO OPERATE UNATTENDED. WHAT CAN HAPPEN HAZARD

AIR TANK: THE FOLLOWING CONDITIONS COULD LEAD TO A WEAKENING OF THE TANK, AND RESULT IN A VIOLENT TANK EXPLOSION AND COULD CAUSE PROP- ERTY DAMAGE OR SERIOUS INJURY. HOW TO PREVENT IT WHAT CAN HAPPEN DRAIN TANK DAILY OR AFTER EACH USE. IF TANK DEVELOPS A LEAK, REPLACE IT IMMEDI- ATELY 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 SPE- CIFIC 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 EQUIP- MENT MANUFACTURERS RECOMMENDATION AND NEVER EXCEED THE MAXIMUM ALLOW- ABLE PRESSURE RATING OF ATTACHMENTS. NEVER USE COMPRESSOR TO INFLATE SMALL LOW-PRESSURE OBJECTS SUCH AS CHILDREN’S TOYS, FOOTBALLS, BASKET- BALLS, ETC. 1. FAILURE TO PROPERLY DRAIN CON- DENSED 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. ATTACHMENTS & ACCESSORIES: EXCEEDING THE PRESSURE RATING OF AIR TOOLS, SPRAY GUNS, AIR OPERATED ACCESSORIES, TIRES AND OTHER INFLATA- BLES CAN CAUSE THEM TO EXPLODE OR FLY APART, AND COULD RESULT IN SERIOUS INJURY. HAZARD RISK FROM FLYING OBJECTS HOW TO PREVENT IT 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. ALWAYS WEAR ANSI Z87.1 APPROVED SAFE- TY 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.

WHAT CAN HAPPEN RISK TO BREATHING AIR OBTAINED DIRECTLY FROM THE COM- PRESSOR 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 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/MSHA APPROVED RESPIRATOR DESIGNED FOR USE WITH YOUR SPECIFIC APPLICATION. THE COMPRESSED AIR DIRECTLY FROM YOUR COMPRESSOR IS NOT SAFE FOR BREATHING. THE AIR STREAM MAY CON- TAIN 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, MAY CONTAIN HARMFUL VAPORS AND POISONS. RISK OF ELECTRICAL SHOCK HOW TO PREVENT IT WHAT CAN HAPPEN YOUR AIR COMPRESSOR IS POWERED BY ELECTRICITY. LIKE ANY OTHER ELECTRI- CALLY POWERED DEVICE, IF IT IS NOT USED PROPERLY IT MAY CAUSE ELECTRIC SHOCK. REPAIRS ATTEMPTED BY UNQUALIFIED PER- SONNEL 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. NEVER OPERATE THE COMPRESSOR OUT- DOORS WHEN IT IS RAINING OR IN WET CON- DITIONS. NEVER OPERATE COMPRESSOR WITH PRO- TECTIVE 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 CIR- CUIT TO WHICH THE COMPRESSOR IS CON- NECTED PROVIDES PROPER ELECTRICAL GROUNDING, CORRECT VOLTAGE AND ADE- QUATE FUSE PROTECTION.

WHAT CAN HAPPEN RISK OF BURNS TOUCHING EXPOSED METAL SUCH AS THE COMPRESSOR HEAD OR OUTLET TUBES, CAN RESULT IN SERIOUS BURNS. NEVER TOUCH ANY EXPOSED METAL PARTS ON COMPRESSOR DURING OR IMME- DIATELY 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. HAZARD HOW TO PREVENT IT WHAT CAN HAPPEN RISK FROM MOVING PARTS 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. MOVING PARTS SUCH AS THE PULLEY, FLY- WHEEL 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 HOW TO PREVENT IT WHAT CAN HAPPEN HAZARD HOW TO PREVENT IT WHAT CAN HAPPEN RISK OF FALLING 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. ALWAYS OPERATE COMPRESSOR IN A STA- BLE SECURE POSITION TO PREVENT ACCI- DENTAL MOVEMENT OF THE UNIT. NEVER OPERATE COMPRESSOR ON A ROOF OR OTHER ELEVATED POSITION. USE ADDI- TIONAL AIR HOSE TO REACH HIGH LOCA- TIONS. RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR 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 TRAIL- ERS. ALWAYS PLACE COMPRESSOR ON A PRO- TECTIVE MAT WHEN TRANSPORTING TO PROTECT AGAINST DAMAGE TO VEHICLE FROM LEAKS. REMOVE COMPRESSOR FROM VEHICLE IMMEDIATELY UPON ARRIVAL AT YOUR DESTINATION. (Fire, Inhalation, Damage to Vehicle Surfaces)

WHAT CAN HAPPEN RISK OF UNSAFE OPERATION REVIEW AND UNDERSTAND ALL INSTRUC- TIONS AND WARNINGS IN THIS MANUAL. BECOME FAMILIAR WITH THE OPERATION AND CONTROLS OF THE AIR COMPRESSOR. KEEP OPERATING AREA CLEAR OF ALL PER- SONS, PETS, AND OBSTACLES. KEEP CHILDREN AWAY FROM THE AIR COM- PRESSOR AT ALL TIMES. DO NOT OPERATE THE PRODUCT WHEN FATIGUED OR UNDER THE INFLUENCE OF ALCOHOL OR DRUGS. STAY ALERT AT ALL TIMES. NEVER DEFEAT THE SAFETY FEATURES OF THIS PRODUCT. EQUIP AREA OF OPERATION WITH A FIRE EXTINGUISHER. DO NOT OPERATE MACHINE WITH MISSING, BROKEN, OR UNAUTHORIZED PARTS. UNSAFE OPERATION OF YOUR AIR COM- PRESSOR COULD LEAD TO SERIOUS INJURY OR DEATH TO YOU OR OTHERS.

30 amps *Fuse Type Time Delay Air Tank Capacity, Gallons 80 ASME, Vertical Approximate Cut-in Pressure 140 PSIG Approximate Cut-out Pressure 175 PSIG SCFM @ 100 psig 17.3 SCFM @ 175 psig 16.8 SPECIFICATIONS 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 deliv- ery. 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 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 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 auto- matically 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 elec- tricity from electrical panel to outlet. To Lock Out Power: Place a lock on the line power switch so no one else can turn on the power. 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 for this unit are available at the store the unit was purchased. ACCESSORIES * 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 compres- sor 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.

(D), from the parts bag. 3. Apply thread sealant tape to the threads of the drain plug exten- sion (D). 4. Assemble the washer (C), drain plug extension (D), and drain plug (B) as shown in Figure. 5. Tighten securely. 6. Remove the oil fill plug (A. 7. Fill the crankcase with the rec- ommended oil. NOTE: Use an air compressor oil such as SAE-30 (API CG/CD heavy duty motor oil). Under extreme winter condi- tions use SAE-20 weight oil. 8. Replace the oil fill plug (A) and tighten securely. A C B ASSEMBLY Tools Required for Assembly 1 - 9/16" socket or open end wrench 1 - electric drill Unpacking 1. Remove all packaging. It may be neces- sary to brace or support one side of the outfit when removing the pallet because the air 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 Compressors are shipped without oil. A small amount of oil may be pres- ent in the pump upon receipt of the 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 fol- low initial start-up procedures. Multi-Viscosity motor oils, like 10W 30, should not be used in an air compressor. They leave carbon deposits on critical components, thus reducing performance and compressor life. Use air compres- sor oil only. 1. Remove the oil drain plug (B) and washer (C). C D B 9-ENG

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 con- crete anchors. 4. Line-up holes in surface with holes in air compressor feet. 5. Place the (4) washers (not sup- plied) 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. 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 sup- plied) 4 - 3/8" Lag screw to fit con- crete anchors (not supplied) 4 - 5/8" Washer (not supplied) - Shims (if needed) Location of the Air Compressor • Locate the air compressor in a clean, dry, and well ventilated area. • Locate the air compressor at least 12" away from the wall or other obstructions that will inter- fere 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 com- pressor. HOW TO SET UP YOUR UNIT 3/8" Lag Screw (not supplied) 5/8" Washer (not supplied) Shim Under Washer (not supplied) Concrete Anchor (not supplied) Surface Line INSTALLATION

a metallic, permanent wiring system, or 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 cir- cuit requirements. Air Distribution System Plastic or PVC pipe is not designed for use with compressed air. Regardless of its indicated pres- sure 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. Wiring Instructions RISK OF ELECTRI- CAL SHOCK. Improper electrical grounding can result in electrical shock. The wiring should be done by a quali- fied 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 elec- trical box should be adequate. Refer to the product specifica- tions, 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 name- plate, 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. Electrical wiring must be located away from hot surfaces such as manifold assembly, compressor outlet tubes, heads, or cylinders.

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. Fill lines with air pres- sure before covering to make sure pipe joints are free from leaks. • Install a flexible coupling between the air discharge outlet and main air distribution line to allow for vibration. NOTE: The shut-off valve is not sup- plied with this unit. You must purch- sase the shut-off valve separately. • A separate regulator is recom- mended to control the air pres- sure. Air pressure from the air tank is usually too high for indi- vidual air driven tools. DRAIN TRAP DRAIN TRAPS DRAIN LEGS MOISTURE SEPARATOR AND TRAP DIRT LEG DIRT LEG LUBRICATOR REGULATOR FILTER AIR DISCHARGE VALVE LUBRICATOR 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. REGULATOR FLEXIBLE COUPLING DRAIN COCK VALVE TYPICAL COMPRESSED AIR DISTRIBUTION SYSTEM AIR FLOW AIR FLOW FEEDER LINES SLOPE WITH AIR FLOW AIR USAGE LINES AIR COMPRESSOR

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 use. Pressure Switch: The pressure switch automatically starts the motor when the air tank pressure drops below the factory set "cut-in" pres- sure. 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 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 (sold separately): Opens and closes air discharge valve. Turn knob counter-clockwise to open and clockwise to close. Regulator (sold separately, not shown): An air pressure regulator or a sepa- rate air transformer which combines the functions of air regulation and/or mois- ture and dirt removal is recommended for most applications. Drain Valve: The drain valve is located at the base of the air tank and is used to drain conden- sation at the end of each use. Cooling System (not shown): This compressor contains an advanced design cooling system. At 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. 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. Globe Valve Tank Pressure Gauge Safety Valve On/Auto/Off Switch Pressure Switch Drain Valve

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. 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". 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. NOTE: The shut-off valve is not supplied with this unit. You must purchase the shut-off valve separately. 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. How to Use Your Unit How to Stop: 1. Set the On/Auto/Off lever to "OFF". Check Valve Pressure Release Valve

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 manu- facturer-s instructions. NOTE: Always operate the air compressor in well-ventilated areas free of gaso- line or other combustible vapors. If the compressor is being used to operate a sprayer, DO NOT place compressor near the spray area. 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 bursting. Check the manufacturer’s maximum pressure rating for air tools and accessories. The regulator outlet pressure must never exceed the maximum pressure rating. 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. 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.

2- more frequent if humidity or operating conditions are extreme. Check Safety Valve Drain Tank Check Oil Change Oil Air Filter NOTE: See "Operation" section for the location of controls. To ensure efficient operation and longer life of the air compressor outfit, a rou- tine maintenance schedule should be prepared and followed. The following routine maintenance schedule is geared to an outfit in a normal working envi- ronment operating on a daily basis. If necessary, the schedule should be modi- fied to suit the conditions under which your compressor is used. The modifica- tions 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. Unit cycles automatically when power is on. When per- forming 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 Check Safety Valve If the safety valve does not work prop- erly, over-pressurization may occur, causing air tank rupture or an explosion. Unusual Noise and/or Vibration Drive Belt-Condition Motor Pulley/Flywheel alignment Air compressor pump intake and exhaust valves Inspect air lines and fittings for leaks ●2 ● ● ● ● ● Head Bolts - Check the torques of the head bolts after the first five hours of operation. Every 500 hours 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.

2. Remove the oil drain plug (B) and drain oil into a suitable container. 3. Replace the oil drain plug (B) and tighten securely 4. Sowly add compressor oil until the oil level is in the middle of the sightglass (C). NOTE: When fill- ing 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. Overfilling with oil will cause prema- ture compressor failure. Do not overfill. 5. Replace oil fill plug (A) and tight- en securely. Oil NOTE: Use a air compressor oil such as SAE-30 (API CG/CD heavy duty motor oil). Under extreme winter con- ditions use SAE-20 weight oil. NOTE: Crankcase oil capacity is approxi- mately 60 fluid ounces (1.8 L). Checking 1. The oil level should be to the mid- dle 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. To Drain Tank NOTE: Operation of the air compres- sor will cause condensation to build up in the air tank. Always drain tank on a washable surface or in a suit- able 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 con- dense in the air tank. If not drained, water will cor- rode 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. B A C C

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 capaci- ty. 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. 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. 4. 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 loca- tion, 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 fol- lowing Pulley and Flywheel - Alignment. 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 loose items get caught in moving parts. Never operate the 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. Downward Force Deflection 6. See the "Adjust Belt Tension" before tightening motor mount- ing screws.

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/pip- ing. 3. Correct any leaks found. IMPORTANT: Even minor leaks can cause the air compressor to over- work, resulting in premature break- down or inadequate performance. Motor Pulley/Flywheel Alignment NOTE: Once the motor pulley has been moved from its factory set loca- tion, 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, per- form 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. 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. 7. Visually inspect the motor drive pulley to verify that it is perpen- dicular 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.

Unit cycles automat- ically 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. Before servicing: Unplug or disconnect electrical supply to the air compressor. Bleed tank of pressure. Allow the air compressor to cool. 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. 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. 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. 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. In closed position disc is visible. In open position nothing is visible. Screwdriver

overload protector. If the motor over- heats 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. 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. Reset Button 4. Place the On/Auto/Off lever in the On/Auto postion to restart the motor. IMPORTANT: If the overload protec- tor 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 run- ning. STORAGE Before you store the air compressor, make sure you do the following: 1. Review the "Maintenance" sec- tion 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 or 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).

parts or compressed air sources, moving parts or compressd air sources. Personal injury may occur. Prior to attempting any repairs, unplug the air compressor and bleed off all air tank air pressure. PROBLEM CAUSE CORRECTION Pressure switch does not shut off motor when com- pressor reaches "cut-out" pressure. Pressure switch "cut-out" too high. 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. Excessive tank pressure - (safety valve) pops off. Tube fittings are not tight enough. Tighten fittings where air can be heard escaping. Check fittings with soapy water solution. DO NOT OVER- TIGHTEN. Air leaks at fittings. Air leaks at pressure switch release valve. (if equipped). Defective pressure switch release valve. Contact a Trained Service Technician. Air leaks in air tank or at air tank welds. Defective air tank. 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. Leaking seal. Contact a Trained Service Technician. Air leaks at or inside check valve. Check valve seat damaged. 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 "Operation" section.

operate acces- sories. 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. 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 fil- ter. Do not operate the air compressor with the filter removed. Refer to the "Air Filter" paragraph in the "Maintenance " section. Pressure reading on the regulated pressure gauge (if equipped) drops when an accessory is used. It is normal for "some" pressure drop to occur. 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). Possible defect in safety valve. Operate safety valve manually by pulling on ring. If valve still leaks, it should be replaced. Air leak from safety valve. Clean or replace. See Air Filter paragraph in the Maintenance section. Dirty air filter. Restricted air intake. Check belt tension, see Adjusting Belt Tension in the Maintenance section. Loose belt. Pressure switch, check valve, or pump could be in need of servicing. Safety Valve on pump "pops" out. Have checked by a Trained Service Technician.

run. Fuse blown, circuit breaker tripped. 1. Check fuse box for blown fuse and replace as nec- essary. Reset circuit breaker. Do not use a fuse or circuit breaker with higher rating than that specified for your particu- lar 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 elec- trical appliances from cir- cuit or operate the com- pressor on its own branch circuit. Motor overload protection switch has tripped. Let motor cool off and over- load switch will automatically reset. Tank pressure exceeds pressure switch "cut-in" pressure. Motor will start automatically when tank pressure drops below "cut-in" pressure of pressure switch. Loose electrical connec- tions. Check wiring connection inside pressure switch and ter- minal box area. Have checked by a Trained Service Technician. Check valve stuck open. Remove and clean, or replace. Possible defective motor or starting capacitor. Have checked by a Trained Service Technician. Do not operate the compressor in the paint spray area. See flamma- ble vapor warning. Paint spray on internal motor parts. Bleed the line by pushing the lever on the pressure switch to the "off" position; if the valve does not open, replace switch. Pressure release valve on pressure switch has not unloaded head pressure.

valve. Operate safety valve manually by pulling on ring. If valve still leaks, it should be replaced. Loose pulley. Tighten pulley set screw, 145-165 in.-lbs. Compressor mounting screws loose. Tighten mounting screws, 20-25 ft.-lbs. Loose flywheel. Tighten flywheel screw, 33-37 ft.-lbs. Loose belt. Check belt tension, see Adjusting Belt Tension in the Maintenance section. Carbon build-up in pump. Have checked by a Trained Service Technician. Belt to tight. Check belt tension, see Adjusting Belt Tension in the Maintenance section. Excessive belt wear. Loose belt. Tight belt. Loose pulley. Have checked by a Trained Service Technician. Pulley misalignment. See Motor Pulley/Flywheel Alignment paragraph in the Maintenace section. Squealing sound. Loose belt. Compressor pump has no oil. See Oil-Checking paragraph in the Maintenace section. Check belt tension, see Adjusting Belt Tension in the Maintenance section. Check belt tension, see Adjusting Belt Tension in the Maintenance section. Check belt tension, see Adjusting Belt Tension in the Maintenance section. Defective check valve. Remove and clean, or replace.

compressor and service part is free from defects in material and workmanship and agrees to repair or replace under this warranty any defective product or part as follows from the original date of purchase. 5 YEARS – Limited warranty on 2-stage oil-free air compressor pumps that operate at 1725 RPM and 1 year limited warranty on all other parts. 3 YEARS – Limited warranty on oil-lubricated air compressor pumps and 1 year limited warranty on all other parts. 1 YEAR – Limited warranty on all other air compressor products. 90 Day – Service parts Engine warranties are the responsibility of the engine manufacturer. Warranties of mer- chandise sold by Porter-Cable which has been manufactured by and identified as the product of another company are the responsibility of the manufacturer of that product. THIS WARRANTY IS NOT TRANSFERABLE AND DOES NOT COVER ● Products sold damaged or incomplete, sold "as is", sold reconditioned or used as rental equipment. ● Delivery, installation or normal adjustments explained in the owner’s manual. ● Damage or liability caused by shipping, improper handling, improper installation, incorrect voltage or improper wiring, improper maintenance, improper modification, or the use of accessories and/or attachments not specifically recommended by PORTER-CABLE for the tool. ● Repairs necessary because of operator abuse or negligence, or the failure to install, operate, maintain and store the product according to the instructions in the owner’s manual. ● Damage caused by cold, heat, rain, excessive humidity, corrosive environments and materials, or other contaminants. ● Expendable items that become worn during normal use such as drain valves, fuses, filters, belts, air cleaners, spark plugs, engine oil and pump oil. ● Cosmetic defects that do not interfere with tool functionality. ● Freight costs from customer to Porter-Cable. ● Repair and transportation costs of products or parts determined not to be defective. ● ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT, FAILURE OR MALFUNC- TION OF THE PRODUCT. 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. ● IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FIT- NESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you. WARRANTY SERVICE is available by delivering or shipping the defective product or part to any Porter-Cable authorized warranty service location. To determine the nearest authorized warranty service location, call the toll free number, 1-888-559-8550, 24 hours a day, 7 days a week. Specific instructions regarding servicing arrangements and sched- uling may vary depending on the type and size of the product and the availability of repair parts. ● DO NOT return the defective product to the retailer. ● Retain the original cash register sales receipt as proof of purchase for warranty work. ● Only Air compressors with 60 and 80 gallon tanks will be inspected at the site of installation. ● The customer should contact Porter-Cable directly if the purchaser does not receive satisfactory results from the authorized warranty service center. ® Porter-Cable Corporation 4825 Highway 45 North P.O. Box 2468 Jackson, TN 38302-2468 1-888-559-8550