Porter Cable Air Compressor CPL55GH8W User Manual

ESPAÑOL: PÁGINA 27  
FRANÇAISE: PAGE 53  
Instruction  
manual  
Oillube  
Compressor  
MODEL  
CPL55GH8W  
IMPORTANT  
Please make certain that the person who is to use this  
equipment carefully reads and understands these  
instructions before starting operations.  
To learn more about Porter-Cable  
visit our website at:  
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  
PROFESSIONAL POWER TOOLS  
Serial No.  
Part No. D26998-031-1  
Copyright © 2003 PORTER-CABLE Corporation  
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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 operation instructions before  
using this equipment.  
HAZARD  
WARNING: Risk of explosion or fire  
What Could Happen  
How To Prevent It  
Turn engine off and allow it to cool  
before adding fuel to the tank. Equip  
area of operation with a fire extinguisher  
certified to handle gasoline or fuel fires.  
Gasoline and gasoline vapors can  
become ignited by coming into contact  
with hot components such as the muffler,  
from engine exhaust gases, or from an  
electrical spark.  
Combustible materials which come into  
contact with hot engine parts can  
become ignited.  
Add fuel outdoors in a well ventilated  
area. Make sure there are no sources of  
ignition, such as cigarettes near refueling  
location.  
Operate compressor in a clean, dry, well  
ventilated area a minimum of forty-eight  
inches from any building, object or wall.  
Do not operate unit indoors or in any  
confined area.  
Operate compressor in an open area  
away from dry brush, weeds or other  
combustible materials.  
Store fuel in a secure location away from  
compressor.  
Always remain in attendance with the  
product when it is operating.  
Unattended operation of this product  
could result in personal injury or prop-  
erty damage. To reduce the risk of fire,  
do not allow the compressor to operate  
unattended.  
3-ENG  
D26998  
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HAZARD  
WARNING: Risk of Bursting  
Air Tank: The following conditions could lead to a weakening of the tank, and result  
in a violent tank explosion and could cause property damage or serious injury.  
What Could Happen  
1. Failure to properly drain condensed  
water from tank, causing rust and  
thinning of the steel tank.  
How To Prevent It  
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.  
2. Modifications or attempted repairs  
Never drill into, weld, or make any modi-  
fications to the tank or its attachments.  
Never attempt to repair a damaged or  
leaking tank. Replace with a new tank.  
to the tank.  
3. Unauthorized modifications to the  
unloader valve, safety valve, or any  
other components which control  
tank pressure.  
The tank is designed to withstand specific  
operating pressures. Never make adjust-  
ments or parts substitutions to alter the  
factory set operating pressures.  
4. Excessive vibration can weaken  
the air tank and cause rupture or  
explosion. Excessive vibration will  
occur if the compressor is not  
properly mounted or if engine oper-  
ates above recommended RPM.  
Do not remove the stiffener bar con-  
necting the compressor pump to the  
engine, except to adjust belt tension,  
Then securely tighten the stiffener bar  
nuts. This bar controls unit vibration.  
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 low pressure  
objects such as children’s toys, footballs,  
basketballs, etc.  
ATTACHMENTS & ACCESSORIES:  
Exceeding the pressure rating of air  
tools, spray guns, air operated acces-  
sories, tires, and other inflatables can  
cause them to explode or fly apart, and  
could result in serious injury.  
4-ENG  
D26998  
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HAZARD  
WARNING: Risk from Flying Objects  
WHAT CAN HAPPEN  
HOW TO PREVENT IT  
Always wear ANSI Z87.1 approved safety  
glasses with side shields when using the  
compressor.  
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, result-  
ing in property damage or personal injury.  
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.  
HAZARD  
WARNING: Risk to Breathing  
WHAT CAN HAPPEN  
HOW TO PREVENT IT  
Always operate air compressor outside  
in a clean, well ventilated area. Avoid  
enclosed areas such as garages, base-  
ments, storage sheds, which lack a steady  
exchange or air. Keep children, pets and  
others away from area of operation.  
Breathing exhaust fumes from engines  
will cause serious injury or death.  
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 breath-  
ing, 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 applica-  
ble local and federal codes prior to  
human consumption.  
The compressed air directly from your  
compressor is not safe for breathing.  
The air stream may contain carbon  
monoxide, toxic vapors, or solid parti-  
cles from the tank. Breathing these cont-  
aminant's can cause serious injury or  
death.  
Work in an area with good cross venti-  
lation. Read and follow the safety  
instructions provided on the label or  
safety data sheets for the materials you  
are spraying. Use a NIOSH/ MSHA  
approved respirator designed for use  
with your specific application.  
Sprayed materials such as paint, paint  
solvents, paint remover, insecticides,  
weed killers, may contain harmful vapors  
and poisons.  
5-ENG  
D26998  
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HAZARD  
WARNING: Risk of Burns  
WHAT CAN HAPPEN  
HOW TO PREVENT IT  
Touching exposed metal such as the  
compressor head, engine head, exhaust  
or outlet tubes, can result in serious  
burns.  
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.  
HAZARD  
WARNING: Risk from Moving Parts  
WHAT CAN HAPPEN  
HOW TO PREVENT IT  
The engine can start accidentally if the  
flywheel is turned by hand or moved by  
pulling on the starter rope.  
Always disconnect the spark plug and  
bleed pressure from the tank before  
performing maintenance.  
Moving parts such as the pulley, flywheel,  
and belt can cause serious injury if they  
come into contact with you or your cloth-  
ing.  
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.  
Attempting to operate compressor with  
damaged or missing parts or attempting  
to repair compressor with protective  
shrouds removed can expose you to mov-  
ing parts and can result in serious injury.  
HAZARD  
WARNING: Risking of Falling  
WHAT CAN HAPPEN  
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.  
A portable compressor can fall from a  
table, workbench or proof causing dam-  
age to the compressor and could result  
in serious injury or death to the opera-  
tor.  
6-ENG  
D26998  
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HAZARD  
WARNING: Risk of Serious Injury or Property Damage when  
Transporting Compressor  
(Fire, Inhalation, Damage to Vehicle Surfaces)  
WHAT CAN HAPPEN  
HOW TO PREVENT IT  
Always place compressor on a protec-  
tive mat when transporting to protect  
against damage to vehicle from leaks.  
Remove compressor from vehicle immedi-  
ately upon arrival at your destination.  
Never lie compressor on its side.  
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.  
HAZARD  
WARNING: Risk of Unsafe Operation  
WHAT CAN HAPPEN  
HOW TO PREVENT IT  
Unsafe operation of your air compressor  
could lead to serious injury or death to  
you or others.  
Review and understand all instructions  
and warnings in this manual.  
Become familiar with the operation and  
controls of the air compressor.  
Keep operating area clear of all persons,  
pets, and obstacles.  
Keep children away from the air compres-  
sor at all times.  
Do not operate the product when  
fatigued or under the influence of alco-  
hol or drugs. Stay alert at all times.  
Never defeat the safety features of this  
product.  
Equip area of operation with a fire extin-  
guisher.  
Do not operate machine with missing,  
broken, or unauthorized parts.  
SPECIFICATIONS  
Model No.  
CPL55GH8W  
Engine Horsepower  
Bore  
Stroke  
5.5  
2.875"  
2.0”  
Air Tank Capacity (Gallon)  
Approximate Unloader Reset Pressure  
Approximate Unloader Blow-off Pressure  
SCFM @ 40 PSIG  
8
110 PSIG  
135 PSIG  
12.0  
SCFM @ 90 PSIG  
10.1  
IMPORTANT: See engine operator’s manual for engine information.  
7-ENG  
D26998  
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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.  
California Code: Unit may comply with California Code 462 (l) (2)/(M) (2).  
Specification/model label is on the side of the tank on units that comply with  
California Code.  
Unloader Blow-Off Pressure: All models are continuous running units con-  
trolled by tank pressure. When the maximum tank pressure is obtained, the  
unloader valve will blow-off. This will cause the compressor to exhaust the air  
to the atmosphere and not the tank. This decreases the load on the engine and  
allows it to run at a near no-load condition.  
Unloader Reset Pressure: When the tank pressure drops to a predetermined  
point, the unloader valve closes. The tank pressure will now increase until it  
reaches the unloader blow-off pressure.  
ACCESSORIES  
Accessories for this unit are available at the store the unit was purchased.  
ASSEMBLY  
Unpacking  
1. Remove unit from carton and discard all packaging. NOTE: Save all parts  
bags.  
The wheels and handle do not provide adequate clear-  
ance, stability or support for pulling the unit up and down  
stairs or steps. The unit must be lifted, or pushed up a ramp.  
Installing Handle  
Do not use the engine gas tank as a support for lifting the  
air compressor.  
1. Push rubber handle grips (L), onto handle tubes (M). Seat firmly. Use a  
twisting motion to ease assembly. See Figure.  
N
M
L
S
R
P
O
8-ENG  
D26998  
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2. Position one handle and grip assembly into clamp on left side of tank  
assembly, as shown in Figure. Align hole in handle with hole in clamp. Insert  
bolt (N) through the hole (in clamp and handle). Thread nut (O) onto bolt.  
Using two 1/2" wrenches (not furnished) tighten nut securely.  
3. Repeat step 2 to assemble remaining handle and grip assembly to the  
clamp on the right side of tank assembly.  
4. Using a 9/16" socket wrench (not furnished) remove the four bolts securing  
the compressor to the shipping skid.  
A.  
B.  
C.  
D.  
Place spacer (S) on flat side of a rubber foot (R). Place spacer and rub-  
ber foot against compressor frame as shown in Figure.  
Align hole in spacer and rubber foot with one of the smaller holes adja-  
cent to the holes where shipping skid was attached.  
Insert one of the 1/4"-20 x 3/4" bolts (P), from the hardware package,  
and using a 3/8" socket wrench (not furnished) tighten firmly.  
Repeat A through C to install the three remaining rubber feet.  
Lubrication and Oil  
Engine  
Drain tank to release air pressure before removing the oil  
fill cap or oil drain plug.  
1. The engine was filled WITH oil at the manufacturer. Check engine oil level  
before operating unit. If necessary, fill engine to the appropriate level with  
recommended oil, see engine manual supplied by engine manufacturer for  
correct procedure.  
2. Add fuel to engine. See engine manual supplied by engine manufacturer for  
correct procedure.  
Gasoline vapor is highly flammable. Refuel outdoors  
preferably, or only in well-ventilated areas. Do not refuel or  
check gasoline level while the engine is running. Do not store, spill, or use  
gasoline near an open flame, a source of sparks (such as welding), or near  
operating electrical equipment.  
Air Compressor  
The air compressor pump was filled WITH oil at the manufacturer. Check air  
compressor pump oil level before operating unit. If necessary, fill pump to the  
appropriate level with approved compressor oil, see the Maintenance section of  
this manual for details.  
9-ENG  
D26998  
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INSTALLATION  
Location of the Air Compressor  
Exhaust from the gasoline engine contains deadly carbon  
monoxide, which is odorless and toxic. Operate engine  
only in well ventilated areas.  
The air compressor must be operated in a clean, dry, and well-ventilated area.  
The air compressor's crankcase and head are designed with cooling fins to pro-  
vide proper cooling. The fan blades of the compressor, the flywheel, must be  
kept clear of obstructions that could interfere with the flow of air through the air  
intake filter.  
Do not install the air compressor in a location where heat is excessive. If  
the humidity in the operating area is high, an air filter can be installed on the air  
outlet adapter to remove excessive moisture. This type air filter is not provided  
with this air compressor and must be purchased separately. Closely follow the  
instructions packaged with the filter for proper installation.  
Do not allow the air compressor to get wet if it is installed  
outdoors.  
Piping  
Plastic or PVC pipe is not designed for use with com-  
pressed air. Regardless of its indicated pressure rating,  
plastic pipe can burst from air pressure. use only metal pipe for air distri-  
bution.  
If a pipe line is necessary, 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 to lines  
before underground lines are buried to make sure all pipe joints are free of leaks.  
10-ENG  
D26998  
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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.  
Air Compressor Pump (not  
D
E
shown): Compresses air into the  
C
air tank.  
Unloader Valve (not shown):  
When the maximum tank pressure  
is obtained, the unloader valve will  
exhaust the compressed air to the  
atmosphere (blow-off). When the  
tank pressure drops to a pre-deter-  
mined point, the unloader valve  
closes and causes the tank pres-  
sure to increase.  
F
Safety Valve (C): If the unloader valve does not release pressure when tank  
reaches "blow-off" pressure, the safety valve will protect against high pressure  
by "popping off" at its factory set pressure (slightly higher than the pressure  
switch blow-off setting).  
Outlet Pressure Gauge (D): The outlet pressure gauge indicates the air pres-  
sure available at the outlet side of the regulator. This pressure is controlled by  
the regulator and is always less than or equal to the tank pressure.  
Tank Pressure Gauge (E): The tank pressure gauge indicates the reserve air  
pressure in the tank.  
Regulator (F): Controls the air pressure shown on the outlet pressure gauge.  
Pull the knob out and turn clockwise to increase pressure and counterclockwise  
to decrease pressure. When the desired pressure is reached push knob in to  
lock in place.  
Drain Valve (not shown): A drain valve is located at the base of each air tank  
and is used to drain condensation at the end of each use.  
Air Intake Filter (not shown): This filter is designed to clean air coming into the  
pump. This filter must always be clean and ventilation openings free from ob-  
structions. See "Maintenance".  
Throttle Control (not shown): A throttle control has been incorporated as an  
extra feature. When maximum tank pressure is reached and the unloader valve  
vents air, it also activates a throttle control on the engine. This gas saving fea-  
ture holds the engine at a factory-set idling speed until air pressure in the air  
tank drops to reset pressure. It then reactivates the throttle control and acceler-  
ates the engine to full throttle.  
11-ENG  
D26998  
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How to Use Your Unit  
How to Stop:  
1. See the engine manufacturer's manual for the procedure to safely shut  
down the gasoline engine. Turning the gasoline engine off will turn off the air  
compressor as well.  
Before First Start-up  
Break-in Procedure  
Serious damage may result if the following break-in  
instructions are not closely followed.  
This procedure is required when:  
1. Before the air compressor is used for the first time.  
2. When the unloader valve is replaced.  
3. When a complete compressor pump is replaced.  
The procedure:  
1. To prevent pressure from building up in the air tanks during this break-in  
period, you must open the unit's unloader valve. Place unloader valve in  
“Open” position as shown.  
2. Open the pressure regulator. Pull regulator  
knob and rotate clockwise until it stops.  
3. Start engine. See engine manual supplied by  
engine manufacturer for correct procedure.  
The air compressor is top  
heavy. Make sure the unit is in  
a stable position and will not tip before pulling  
the starter cord of the engine.  
Open  
4. Make sure the unloader valve is in the “Open” position to prevent tank  
pressure buildup.  
5. Run the air compressor for 30 minutes to seat the rings and lubricate all  
the internal surfaces. Make sure there is no pressure build up in the tank by  
observing the reading on the tank pressure gauge.  
6. Place unloader valve in the “Closed” position as shown.  
7. Close the pressure regulator. Rotate the regulator  
knob counter-clockwise to its built-in stop and  
push knob in to lock in place. This will allow air to  
build pressure in the air tanks.  
NOTE: When the air tank is pressurized, the tank pres-  
sure gauge will indicate the pressure available in the air  
tank and the gasoline engine will reduce its speed to  
idle and keep running. The pressurization of the air tank  
will be adjusted automatically by the "reset" and "blow  
off" setting of the unloader valve. When the pressure in  
Closed  
the air tank drops to the "reset" value, the gasoline engine will increase its rpm  
to operate the compressor and pressurize the tanks. When the pressure in the  
air tank increases to the "blow off" value, the engine rpm will drop to idle.  
NOTE: Consult the engine manufacturer's manual for the proper engine  
break-in running time and oil change interval for the engine used on your  
air compressor as well as other engine maintenance requirements.  
12-ENG  
D26998  
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8. Compressed air will be available from the unit's outlet valve until it is used  
up or bled off. The compressor is now ready for use.  
Before each start-up  
Perform the following checks before starting the air compressor.  
1. Make sure nothing is blocking the belt guard, air openings, or air filter inlet.  
2. Make sure the unloader valve moves freely and smoothly.  
3. Check the oil level in the pump and engine, add oil if necessary.  
Temperature of muffler and near by areas my exceed  
150°F (65°C) avoid these areas.  
4. Clean or blow off fins or any part of the air compressor that collects dust  
and dirt. The air compressor will run cooler and provide longer service.  
5. Open the unloader valve of the air compressor before starting the engine.  
To start-up  
6. Start the engine (see engine manual supplied by engine manufacturer for  
correct procedure) and close unloader to allow tank pressure to pump up to  
blow-off pressure.  
Unit is top heavy. Make sure the compressor is stable and  
will not tip before pulling the starting cord.  
Too much air pressure causes a hazardous risk of burst-  
ing. Closely monitor the air pressure gauge of the tank so  
the maximum pressure limit is not exceeded and monitor the safety valve  
to ensure excess pressure is discharged. If pressure continues to build  
beyond safe limits, shut the unit down immediately and troubleshoot the  
problem.  
7. Check all fittings and piping for air leaks. Even minor leaks can cause the  
air compressor to overwork, resulting in premature breakdown or unsatis-  
factory performance.  
8. Check for any unusual vibration and noise.  
9. Check for oil leaks and correct any leaks found.  
10. Check the pressure ratings of the air tools and accessories being used with  
this air compressor before attaching, then adjust the shut-off valve for that  
value.  
The air compressor's outlet pressure must never exceed  
the maximum pressure rating of the tool or accessory  
being used. If a pressure regulator is not used, do not use accessories  
rated at less than 110 psi.  
11. Attach air hose and accessory. Your unit is ready for use.  
Compressed air from the unit may contain water conden-  
sation and oil mist. Do not spray unfiltered air at an item  
that could be damaged by moisture. Some air operated tools or devices  
may require filtered air. Read the instructions for the air tool or device.  
Shutting Down  
12. Turn off engine.  
13. Close the pressure regulator.  
14. Remove the air tool or accessory.  
15. Open pressure regulator and allow air to slowly bleed from the tank. Close  
the regulator when the tank pressure is approximately 20 PSIG.  
13-ENG  
D26998  
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Drain air tank daily. Water will condense in air tank. If not  
drained, water will corrode and weaken the air tank caus-  
ing a risk of tank rupture.  
16. With tank pressure at approximately 20 PSIG, open the drain valves and  
allow moisture to drain.  
NOTE: If drain cock is clogged, release all air pressure. The drain cock can  
then be removed, cleaned, and reinstalled.  
17. After the water has been drained, close the drain cocks. The air compressor  
can now be stored.  
14-ENG  
D26998  
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MAINTENANCE  
Customer Responsibilities  
Daily or  
after  
each  
use  
Before  
each  
use  
Every Every Every Every  
Yearly  
8
40  
100  
160  
hours hours hours hours  
Check Safety Valve  
Drain Tank  
Oil Leaks  
Check Pump Oil  
Change Pump Oil  
1
Unusual Noise and/or Vibration  
Air Filter  
1
Drive Belt -Condition  
Motor Pulley/Flywheel alignment  
Inspect air lines and fittings  
for leaks  
Air compressor pump intake  
and exhaust valves  
1- more frequent in dusty or humid conditions  
Consult the Engine Owners Manual for the manufacturer's recommendations  
for any and all engine maintenance.  
During maintenance, you could be exposed to compressed  
air or moving parts. Personal injuries can occur. Before  
doing any maintenance or repair, disconnect the spark plug wire to prevent  
accidental starting, and relieve air tank pressure. Never operate the com-  
pressor with the belt guard removed.  
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 units in an extremely dirty and/or hostile environment will require a  
greater frequency of all maintenance checks.  
NOTE: See "Operation"section for the location of controls.  
To Check Safety Valve  
If the safety valve does not work properly, over-pressuriza-  
tion 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 oper-  
ate smoothly, it must be replaced with the same type of valve.  
15-ENG  
D26998  
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To Drain Tank  
1. Turn off engine.  
2. Remove the air tool or accessory.  
3. Pull ring on safety valve allowing air to bleed from the tank until tank pres-  
sure is approximately 20 psi. Release safety valve ring.  
4. 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.  
5. 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  
Drain tank to release air pressure before removing the oil  
fill cap or oil drain plug.  
Checking  
1. Remove the oil fill plug (A). The oil level should be even  
with the top of the fill hole and no lower than 6 threads  
from the top of fill hole.  
A
2. If needed, slowly add oil until it reaches the top of fill hole.  
NOTE: Use an oil specifically formulated for use in an air com-  
pressor, such as Sears 9-16426 air compressor oil.  
Changing  
1. Remove the oil fill plug (A).  
B
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. Slowly fill crankcase to the top of the fill hole. Crankcase capacity is 16  
fluid ounces (473.2 ml).  
Overfilling with oil will cause premature compressor fail-  
ure. Do not overfill.  
5. Replace oil fill plug (A) and tighten securely.  
16-ENG  
D26998  
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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.  
Keep the air filter clean at all times. Do not operate the air  
compressor with the air filter removed.  
A dirty air filter will not allow the compressor pump to operate at full  
capacity. Before using the compressor pump, check the air filter to make  
sure it is clean and in place.  
If it is dirty, replace it with a new filter.  
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 cor-  
rect part number.  
4. Replace air filter cover and lock into place.  
Air Compressor Pump Intake and Exhaust Valves  
Once a year have a Trained Service Technician check the air compressor pump  
intake and exhaust valves.  
17-ENG  
D26998  
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SERVICE AND ADJUSTMENTS  
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE PER-  
FORMED BY TRAINED SERVICE TECHNICIAN.  
Before servicing:  
• Stop engine.  
• Bleed tank of pressure.  
• Allow the air compressor to cool.  
Safety Valve-Inspection and Replacement  
If the safety valve does not work properly, over-pressuriza-  
tion can occur and cause air tank rupture or explosion.  
Daily pull the ring on the safety valve and make sure it operates freely. If  
the valve is stuck or does not operate smoothly, it must be replaced with  
the same type of valve having an identical pressure rating.  
To Remove Safety Valve:  
1. Make sure the air compressor  
unit is off and disconnect the  
spark plug wire.  
A
2. Open the outlet valve and allow  
all air to bleed from the tank.  
Monitor tank pressure gauge as  
tank is emptied.  
3. When tank is empty, remove  
safety valve (A) from manifold.  
Refer to Figure.  
To Install New Safety Valve:  
1. Verify new safety valve is the  
correct pressure rating for your air compressor.  
2. Verify threads for safety valve in manifold are clean.  
3. Apply thread sealant to the threads of new safety valve.  
4. Install new valve and hand-tighten.  
5. Tighten nut to secure safety valve to manifold. Do not overtighten.  
6. Reconnect spark plug wire to engine.  
7. Perform the Daily Start Up Checklist.  
18-ENG  
D26998  
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Belt – Replacement and Adjustment  
Serious injury or damage may occur if parts of the body or  
loose items get caught in moving parts. Never operate the  
unit with the belt guard removed. the belt guard should be removed only  
when the air compressor is turned off the spark plug wire is disconnected.  
Belt Guard – Removal  
1. Disconnect the spark plug wire on the engine and release all air tank pres-  
sure.  
B
2. Remove the six screws (A) from  
the belt guard. The front of the  
belt guard can now be  
removed.  
Belt – Replacement  
1. Disconnect the spark plug wire  
A
on the engine and release all air  
tank pressure.  
2. Remove the front of the belt  
guard as previously described.  
3. Mark engine position on sad-  
dle.  
4. Loosen stiffener bracket screw on  
engine.  
5. Being careful not to remove the stiffen-  
er plate under the saddle, loosen the  
six engine mounting bolts (C).  
6. Slide engine toward pump to remove  
tension from the belt, and then remove  
the old belt.  
7. Install the new belt over the pulleys.  
NOTE: The belt must be centered over  
the grooves on the engine pulley and flywheel.  
C
8. Slide the engine back into its regular position. Line the engine up with the  
mark made earlier on saddle.  
Belt Tension - Adjustment  
1. Slide the engine back into its regular position. Line the engine up with the  
mark made earlier on saddle.  
2. Hold belt tension and secure-  
ly tighten two engine mount-  
ing bolts.  
3. Measure correct belt tension.  
Proper tension is achieved  
when a three (3) pound  
weight or equivalent finger  
pressure applied midway  
between the motor pulley  
and compressor flywheel  
causes a 1/4" deflection of  
the belt. Refer to Figure 10.  
19-ENG  
D26998  
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4. When proper belt tension is achieved, tighten the remaining engine mount-  
ing bolts.  
5. Tighten stiffener bracket screw.  
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.  
Pulley and Flywheel - Alignment  
The air compressor flywheel and engine 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. Disconnect the spark plug wire on the engine and release all air tank pres-  
sure.  
2. Remove belt guard.  
3. Place a straightedge  
against the outside of  
the flywheel and the  
engine 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 setscrew holding  
the engine 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 engine drive pulley setscrew to 70-80 in.-lbs.  
7. Visually inspect the engine 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 engine drive pulley and  
equalize B1 and B2, using care not to disturb the belt alignment performed  
in step 2.  
8. Retighten the engine drive pulley setscrew to 70-80 in.-lbs.  
9. Reinstall belt guard.  
10. Reconnect spark plug wire to spark plug on engine.  
20-ENG  
D26998  
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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. Review the "Engine Manufacturer's Operating and Maintenance  
Instructions".  
3. Remove the air tool or accessory.  
4. Pull ring on safety valve allowing air to bleed from the tank until tank pres-  
sure is approximately 20 psi. Release safety valve ring.  
5. Drain water from air tank by opening drain valve 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.  
6. 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.  
7. Wind air hose around hose wrap and secure in place.  
8. Store the air compressor in a clean and dry location.  
21-ENG  
D26998  
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TROUBLESHOOTING  
Performing repairs may expose voltage sources, moving  
parts or compressed air sources, moving parts or com-  
pressed air sources. Personal injury may occur. Prior to attempting any  
repairs, unplug the air compressor and bleed off all air tank air pressure.  
CORRECTION  
CAUSE  
PROBLEM  
Excessive tank  
pressure-safety  
valve pops off.  
Unloader valve does not  
release pressure when tank  
reaches "blow-off" pressure.  
Unloader valve must be  
replaced.  
Tighten fittings where air can  
be heard escaping. Check  
fittings with soapy water  
solution. DO NOT OVER-  
TIGHTEN.  
Air leaks at  
fittings.  
Tube fittings are not tight  
enough.  
Continuous air  
leak at unloader  
valve.  
Defective unloader valve.  
Turn off engine, move  
unloader valve toggle lever  
to vertical position. If air  
leaks out of tank through  
unloader valve, clean or  
replace unloader valve.  
Air tank must be replaced.  
Do not repair the leak.  
Do not drill  
Air leaks in air  
tank or at air  
tank welds.  
Defective air tank.  
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 from  
safety valve.  
Possible defect in safety  
valve.  
Operate safety valve manual-  
ly by pulling on ring. If valve  
still leaks, it should be  
replaced.  
22-ENG  
D26998  
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CORRECTION  
CAUSE  
PROBLEM  
Decrease amount of air usage.  
Prolonged excessive use of  
air.  
Compressor is not large  
enough for air requirement.  
Compressor is  
not supplying  
enough air to  
operate acces-  
sories.  
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.  
Hole in hose.  
Unloader valve restricted.  
Air leaks.  
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  
Restricted air intake filter  
“Maintenance “ section.  
Check belt tension, see  
Adjusting Belt Tension in the  
Maintenance section.  
Loose belt.  
Clean or replace. See Air Filter  
paragraph in the Maintenance  
section.  
Restricted air  
intake.  
Dirty air filter.  
Excessive  
vibration.  
Engine or pump mounting  
screws are loose.  
Excessive  
vibration  
could weaken the air tank  
and cause it to rupture or  
explode. Stiffener bar nuts  
and mounting screws must  
be kept tightened. Never  
operate the unit unless  
equipped with the stiffener  
bar and rubber feet.  
Stiffener bracket screw is  
loose.  
23-ENG  
D26998  
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CORRECTION  
CAUSE  
PROBLEM  
Knocking Noise. Possible defect in safety  
valve.  
Operate safety valve manually  
by pulling on ring. If valve still  
leaks, it should be replaced.  
Tighten pulley set screw, see  
Parts manual for torque speci-  
fications.  
Loose pulley.  
Tighten flywheel screw, see  
Parts manual for torque speci-  
fications.  
Loose flywheel.  
Compressor or engine  
mounting screws loose.  
Tighten mounting screws,see  
Parts manual for torque speci-  
fications.  
Loose belt.  
Check belt tension, see  
Adjusting Belt Tension in the  
Maintenance section  
Carbon build-up in pump.  
Belt to tight.  
Have checked by a Trained  
Service Technician.  
Check belt tension, see  
Adjusting Belt Tension in the  
Maintenance section  
Check both nuts and tighten if  
required.  
Stiffener bar loose.  
Low oil level (compressor  
or engine)  
Maintain prescribed oil level.  
Add oil.  
Excessive belt  
wear.  
Loose belt.  
Tight belt.  
Check belt tension, see  
Adjusting Belt Tension in the  
Maintenance section  
Check belt tension, see  
Adjusting Belt Tension in the  
Maintenance section  
Loose pulley.  
Have checked by a Trained  
Service Technician.  
See Motor Pulley/Flywheel  
Alignment paragraph in the  
Maintenance section.  
Pulley misalignment.  
24-ENG  
D26998  
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CORRECTION  
CAUSE  
PROBLEM  
Squealing  
sound.  
See Oil-Checking paragraph in  
the Maintenance section.  
Compressor pump has no  
oil.  
Check belt tension, see  
Adjusting Belt Tension in the  
Maintenance section  
Loose belt.  
Engine will not  
run.  
The gasoline tank is empty. Fill the tank with gas.  
The choke is not set prop-  
erly.  
Re-set the choke. Remember,  
a warm engine requires less  
choking that a cold engine.  
Air tank pressure is too  
high.  
Open the ball valve and reduce  
tank pressure to less than 40  
psig.  
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).  
It is normal for “some”  
pressure drop to occur.  
Pressure reading  
on the regulated  
pressure gauge  
(if equipped)  
drops when an  
accessory is  
used.  
Regulator knob Damaged regulator  
has continuous  
Replace  
air leak.  
Damaged regulator  
Replace  
Regulator will  
not shut off air  
outlet.  
25-ENG  
D26998  
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LIMITED WARRANTY  
PORTER-CABLE CORPORATION warrants to the original purchaser that all products covered under this  
warranty are free from defects in material and workmanship. Products covered under this warranty include air  
compressors, air tools, service parts, pressure washers, and generators, which have the following warranty  
periods:  
3 YEARS - Limited warranty on 2-stage oil-free air compressor pumps that operate at 1725 RPM.  
2 YEARS - Limited warranty on oil-lubricated air compressor pumps.  
1 YEAR - Limited warranty on all other air compressor components.  
2 YEARS - Limited warranty on electric generator alternators.  
1 YEAR - Limited warranty on other generator components.  
2 YEARS - Limited warranty on pneumatic air tools as described in Porter-Cable general catalog.  
1 YEAR - Limited warranty on pressure washers used in consumer applications (i.e. personal residential  
household usage only).  
90 DAY - Pressure washers used for commercial applications (income producing) and service parts.  
1 YEAR - Limited warranty on all accessories.  
Porter-Cable will repair or replace, at Porter-Cable's option, products or components which have failed with-  
in the warranty period. Service will be scheduled according to the normal work flow and business hours  
at the service center location, and the availability of replacement parts. All decisions of Porter-Cable  
Corporation with regard to this limited warranty shall be final.  
This warranty gives you specific legal rights, and you may also have other rights which vary from state to  
state.  
RESPONSIBILITY OF ORIGINAL PURCHASER (initial User):  
To process a warranty claim on this product, DO NOT return it to the retailer. The product must be evaluat-  
ed by a Porter-Cable Authorized Warranty Service Center. For the location of the nearest Porter-Cable  
Authorized Warranty Service Center call 1-888-559-8550, 24 hours a day, 7 days a week.  
Retain original cash register sales receipt as proof of purchase for warranty work.  
Use reasonable care in the operation and maintenance of the product as described in the Owners  
Manual(s).  
Deliver or ship the product to the nearest Porter-Cable Authorized Warranty Service Center. Freight costs,  
if any, must be paid by the purchaser.  
Air compressors with 60 and 80 gallon tanks will be inspected at the site of installation. Contact the near-  
est Porter-Cable Authorized Warranty Service Center that provides on-site service calls, for service call  
arrangements.  
If the purchaser does not receive satisfactory results from the Porter-Cable Authorized Warranty Service  
Center, the purchaser should contact Porter-Cable.  
THIS WARRANTY DOES NOT COVER:  
Merchandise sold as reconditioned, used as rental equipment, and floor or display models.  
Merchandise that has become damaged or inoperative because of ordinary wear, misuse*, cold, heat, rain,  
excessive humidity, freeze damage, use of improper chemicals, negligence, accident, failure to operate  
the product in accordance with the instructions provided in the Owners Manual(s) supplied with the prod-  
uct, improper maintenance, the use of accessories or attachments not recommended by Porter-Cable, or  
unauthorized repair or alterations.  
*
An air compressor that pumps air more than 50% during a one hour period is considered misuse  
because the air compressor is undersized for the required air demand.  
Repair and transportation costs of merchandise determined not to be defective.  
Costs associated with assembly, required oil, adjustments or other installation and start-up costs.  
Expendable parts or accessories supplied with the product which are expected to become inoperative or  
unuseable after a reasonable period of use, including but not limited to sanding disks or pads, saw and  
shear blades, grinding stones, springs, chisels, nozzles, o-rings, air jets, washers and similar accessories.  
Merchandise sold by Porter-Cable which has been manufactured by and identified as the product of  
another company, such as gasoline engines. The product manufacturer's warranty, if any, will apply.  
ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY  
RESULT FROM ANY DEFECT, FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT COVERED BY  
THIS WARRANTY. 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 OR FITNESS FOR A PARTICU-  
LAR 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.  
Porter-Cable Corporation  
Jackson, TN USA  
1-888-559-8550  
26-ENG  
D26998  
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