Instruction Sheet 60800-60802 Rear Leaf Spr

Installation Instructions for 81966
Pancake Air Compressor
6 Gallon 1.5 HP
IMPORTANT SAFETY INSTRUCTIONS AND GUIDELINES
This manual contains information that relates to PROTECTING YOUR SAFETY and PREVENTING EQUIPMENT
PROBLEMS and is very important for you to know and understand.
DANGER POTENTIAL HAZARD THAT WILL RESULT IN SERIOUS INJURY OR LOSS OF LIFE
WARNING POTENTIAL HAZARD THAT COULD RESULT IN SERIOUS INJURY OR LOSS OF LIFE
CAUTION POTENTIAL HAZARD THAT MAY RESULT IN MODERATE INJURY OR DAMAGE TO EQUIPMENT
DANGER
This compressor/pump is not equipped and should not be used to supply breathing quality air. Additional equipment
would be necessary to properly filter and purify the air to meet minimal specifications for Grade D breathing as
described in Compressed Gas Association Commodity Specification G 7.1 - 1966, OSHA 29 CFR 1910.134.
Compressed Gas Association, 4221 Walney Road, Fifth Floor, Chantilly, VA 20151-2923, (703) 788-2700,
www.cganet.com. Any such additional equipment has not been examined and no implication of proper use for breathing
air is intended or implied.
WARNING
1. RISK OF EXPLOSION OR FIRE. Never spray flammable liquids in a confined area. It is normal for the motor and
pressure switch to produce sparks while operating. If sparks come into contact with vapors from gasoline or other
solvents, they may ignite and cause a fire or explosion. Do not smoke while spraying. Do not spray where sparks or
flame are present. Keep compressor as far from spray area as possible. Always operate the compressor in a wellventilated area.
2. RISK OF ELECTRIC SHOCK. A licensed electrician in accordance with all local and national codes must install all
wiring. To avoid electric shock, NEVER use an electric air compressor outdoor when it is raining or on a wet surface.
3. RISK OF BURSTING. Rust can weaken the tank. Drain the condensed water from the tank after each use to reduce
rusting. DO NOT weld, drill or modify the air tank of this compressor. Welding or modifications on the air tank can
severely impair tank strength and cause an extremely hazardous condition. If a leak is detected in the tank, replace the
tank right away.
4. RISK OF INJURY. ALWAYS shut off the compressor, remove the plug from the outlet and bleed all pressure from
the system before servicing the compressor or when the compressor is not in use. Do NOT use the unit with the
shrouds removed. Contact with moving parts could cause serious injury.
5. RISK OF BURSTING. Check the maximum pressure rating in the manual or the serial tag label. Compressor outlet
pressure must be regulated so as to never exceed the maximum pressure rating. Relieve all pressure through the hose
before removing or attaching accessories.
6. RISK OF BURSTING. DO NOT adjust the pressure switch or relief valve for any reason. They have been preset at
the factory for the maximum pressure of this unit. If the pressure switch or the relief valve are tampered with, personal
injury or property damage may occur.
7. RISK OF BURNS. Pump and manifold generate high temperature. To avoid burns or other injuries, DO NOT touch
the pump, manifold or transfer tube while the unit is running. Allow the parts to cool before handling or servicing. Keep
children away from the compressor at all times.
8. RISK TO BREATHING. Be certain to read all labels when you are spraying paints or toxic materials, and follow the
safety instructions. Use a respirator mask if there is a chance of inhaling anything you are spraying. NEVER directly
inhale the compressed air produced by a compressor.
9. RISK OF EYE INJURY. ALWAYS wear ANSI Z87.1 approved safety goggles when using an air compressor. NEVER
point nozzle or sprayer toward a person or any part of the body. If the spray penetrates the skin, serious injury may
occur.
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CAUTION
1. Pull the pressure relief valve ring daily to ensure that the valve is functioning properly.
2. The unit must be kept a minimum of 12 inches from the nearest wall, in a well-ventilated area for cooling.
3. Protect the air hose and electric cord from damage and puncture. Inspect them weekly for weak or worn spots and
replace if necessary.
4. Always wear hearing protection when using an air compressor. Failure to do so may result in hearing loss.
5. Operation of the unit should always be in a position that is stable. Never use the unit on a rooftop or elevated
position that could allow the unit to fall or be tipped over.
BASIC COMPRESSOR FEATURES
A. ELECTRIC MOTOR: The motor is used to power the pump. It contains a thermal overload protector and an
automatic reset. If the motor overheats for any reason, the thermal overload protector will shut it down to prevent the
motor from being damaged. The motor will automatically restart when it completely cools.
AIR COMPRESSOR PUMP: The pump is used to compress the air and discharge it into the tank via the piston
moving up and down in the cylinder.
B. AIR TANK: The tank is used to store the compressed air.
C. TANK PRESSURE GAUGE: The gauge is used to measure the stored air pressure level of the tank. It is not
adjustable by the operator, and does not indicate line pressure.
D. AIR PRESSURE REGULATOR: The regulator is used to adjust line pressure to the tool you are using. Turn the
knob clockwise to increase pressure and counterclockwise to decrease pressure.
WARNING: Never exceed the maximum working pressure of the tool.
E. REGULATED PRESSURE GAUGE: The gauge is used to measure the regulated outlet pressure.
F. AIR LINE OUTLET: The outlet is used to connect 1/4" NPT air hose.
G. AIR TANK DRAIN VALVE: The drain valve is used to remove moisture from the air tank after the unit is shut off.
WARNING: Never attempt to open the drain valve when the tank pressure is over 10 PSI.
H. PRESSURE RELIEF VALVE: The valve is used to prevent system failures by relieving pressure from the system. If
the pressure reaches the preset level and the pressure switch will not shut down the motor, it will automatically pop
open. You can also pull the ring on the valve to open.
I. ON/OFF SWITCH: This switch turns on the compressor and is operated manually. When in the ON position, it allows
the compressor to start up or shut down automatically, without warning, upon air demand. ALWAYS set this switch to
OFF when the compressor is not being used, and before unplugging the compressor.
J. POWER CORD: This product is for use on a nominal 120-volt circuit and should
be grounded. A cord with a grounding plug as illustrated must be used. Make sure
that the product is connected to an outlet having the same configuration as the plug
(see Figure 1). No adapter should be used with this product. Check with a licensed
electrician if the grounding instructions are not 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 licensed electrician.
DANGER: Improper installation of the grounding plug will result in a risk of electric
shock. If repair or replacement of the cord or plug is necessary, do not connect the
grounding Pin Grounding wire to either flat blade terminal. The grounding wire is in
the green outer surface.
Figure 1
CAUTION: This compressor is intended to be used at a duty cycle 50%.
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SPECIFICATIONS
Electrical Rating
Air Outlet Size
120V AC/60Hz/9.7A
1/4"-18NPT
Air Pressure Shut-off 150PSl
Air Pressure Restart
120PSl
Air Tank Capacity
6 Gallons
Air Flow Capacity
2.5 SCFM @ 90PSl
3.4 SCFM @ 40PSl
Sound Level
90 dB @ 3'
INSTRUCTIONS
Read the ENTIRE IMPROTANT SAFETY INFORMATION section at the beginning of this manual including all text
under subheadings therein before set up or use of this product
WARNING: TO PREVENT SEROUS INJURY FROM ACCIDENTAL OPERATION: Turn the Power Switch "OFF" and
unplug the Air compressor from its electrical outlet before assembling or making any adjustments to the compressor.
OIL-FREE UNIVERSAL MOTOR
Your air compressor features permanently lubricated bearings.
PRESSURE REGULATOR KNOB
Use the pressure regulator knob to adjust the amount of air being delivered through the hose.
PRESSURE RELIEF VALVE
The pressure relief valve is designed to automatically release air if the air receiver pressure exceeds the preset
maximum.
REGULATOR PRESSURE GAUGE
The current line pressure is displayed on the regulator pressure gauge. This pressure can be adjusted by rotating the
pressure regulator knob.
The tank pressure gauge indicates the pressure of the air in the tank.
Handle
Safety Valve
Pressure Regulator Knob
On/Off Switch
Tank Pressure
Gauge
Locking Nut
Output Pressure
Gauge
Quick Coupler
Tank
Drain Valve
Rubber Foot
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1. Break in the new Air compressor as follows:
a. Turn the Power Switch off and unplug the unit. Insert a male coupler (Sold separately) into the female Quick
Coupler and fully open all regulators and valves.
b. Plug in the Power Cord.
c. Turn the Power Switch ON.
d. Let the unit run for 30 minutes.
Air will expel freely through the coupler.
e. Turn the Power Switch OFF.
f. Unplug the Power Cord and remove the male coupler
2. Connect a regulator valve, an inline shut off valve and a 1/4" NPT air hose to the Quick Coupler (all sold separately).
The air hose must be long enough to reach the work area with enough extra length to allow free movement while
working.
NOTE: An in-line shutoff ball valve is an important safety device because it controls the air supply even if the air hose is
ruptured. The shutoff valve should be a ball valve because it can be closed quickly.
3. Depending on the tool which you will be using with this compressor, you may need to incorporate additional
components, such as an in-line oiler, a filter, or a dryer (all sold separately)
MAINTENANCE
WARNING
To avoid personal injury, always shut off and unplug the unit and relieve all air pressure from the system before
performing any service on the air compressor.
Regular maintenance will ensure trouble free operation. The items listed in the chart should be inspected on a regular
basis
ITEM
DESCRIPTION
To prevent corrosion inside the tank, the condensation must be drained at the end of every
Drain the
workday. Be sure to wear protective goggles. Relieve the air pressure in the system and open
tank
the drain valve on the bottom of the tank.
Check the Pull the relief valve on the ring daily to ensure that it is operating properly and to clear the
relief valve valve of any possible obstructions.
SERVICE
INTERVAL
Daily
Daily
Check all connections to see if tight. A small leak of part (the tank, hoses, pipe connections or
transfer tubes) will reduce the unit's performance.
Test for
leakage
Storage
N/A
Spray a small amount of soapy water around the area of the suspected leak with a spray
bottle. If bubbles appear, repair or replace the faulty component. Do not over tighten any
connections.
Before storing the unit for a long period, use an air blow gun to clean all dust and debris from
the compressor. Disconnect and coil the power cord up. Pull the pressure relief valve to
release all pressure from the tank. Drain all moisture from the tank. Cover the entire unit to
protect it from moisture and dust.
N/A
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COMMON TERMS
Air Filter
Porous element contained within a metal or plastic housing attached to the compressor cylinder head which removes
impurities from the intake air of the compressor.
Air Tank
Cylindrical component which contains the compressed air.
Check Valve
Device that prevents compressed air from flowing back from the air tank to the compressor pump.
Cut-In Pressure
The low pressure at which the motor will automatically restart.
Cut-Off Pressure
The high pressure at which the motor will automatically shut off.
Electric Motor
Device which provides the rotational force necessary to operate the compressor pump.
Manual On/Off Switch
Control which turns the air compressor on or off. The pressure switch will not automatically start and control the
compressor unless the manual On/Off Switch is in the ON position.
NPT (National Pipe Thread)
A seal thread tape must be used to provide a leak-free seal on pipe threaded connections.
SCFM (Standard Cubic Feet Per Minute)
A unit of measure of air delivery.
Pressure Regulator Knob
Regulates the outgoing pressure from the air outlet to the tool. It is possible to increase or decrease the pressure at the
outlet by adjusting this control knob.
Pressure Switch
Automatically controls the on/off cycling of the compressor. It stops the compressor when the cut-off pressure in the
tank is reached and starts the compressor when the air pressure drops below the cut-in pressure.
PSI (Pounds Per Square Inch)
Measurement of the pressure exerted by the force of the air. The actual psi is measured by a pressure gauge on the
compressor.
Pump
Produces the compressed air with a reciprocating piston contained within the cylinder.
Regulator Pressure Gauge
Displays the current line pressure. Line pressure is adjusted by rotating the pressure regulator knob.
Pressure Relief Valve
Prevents air pressure in the air tank from rising over a predetermined limit.
Tank Pressure Gauge
Indicates the pressure in the air tank.
Thermal Overload Switch
Automatically shuts off the compressor if the temperature of the electric motor exceeds a predetermined limit.
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TROUBLESHOOTING CHART
NOTE: Troubleshooting problems may have similar causes and solutions.
PROBLEM
POSSIBLE CAUSE
Tank drain valve is open
Fittings leak
Low pressure or not
enough air or
compressor does not
stop
Restricted air intake
Prolonged or excessive use
of air
Compressor not large
enough
Hole in air hose
Tank Leaks
Blown seals
Valve leaks
Leaking or worn piston
Air leaks from regulator,
Dirty or damaged regulator
or regulator does not
internal parts
regulate pressure
Regulated
pressure gauge reading
drops when air
accessory is being used
Pressure relief valve
opens
Motor will not run
This is normal
Compressor not large
enough
SOLUTION
Close tank drain valve.
Check fittings with soapy water. Tighten or reseal leaking
fittings.
DO NOT OVERTIGHTEN!
Clean or replace air filter element.
Decrease amount of air used.
Check air requirement of accessory. If it is higher than CFM and
pressure supplied by compressor, you need a larger
compressor. Most accessories are rated at 25% of actual CFM
while running continuously.
Check and replace if necessary
WARNING Immediately replace tank.
DO NOT attempt to repair
Replace compressor assembly.
Replace compressor assembly.
Replace compressor assembly.
Replace regulator or internal parts.
If pressure drops to low, adjust regulator while accessory is
used.
Check air requirement of accessory. If it is higher than CFM and
pressure supplied by compressor, you need a larger
compressor. Most accessories are rated at 25% of actual CFM
while running continuously.
Tank pressure exceeded
Replace pressure switch.
normal rating pressure
Pressure switch stuck
Replace pressure switch.
Tank pressure exceeds
Motor will start automatically when tank pressure drops below
preset pressure switch limit
tank cut-in pressure.
Motor overload protection Let motor cool off and overload switch will automatically reset.
has tripped
This may take several minutes.
Replace blown fuse or reset circuit breaker. Do not use fuse or
circuit breaker with higher rating than specified for your branch
circuit.
Check for proper fuse:
Fuse blown or circuit
"Fusetron" type T is acceptable
breaker tripped
Check for low voltage and proper extension cord size.
Disconnect other applications from circuit. Operate compressor
on a dedicated circuit.
Check valve is stuck open
Remove and clean or replace.
Pressure bleeder valve on
Bleed line by moving pressure switch lever to OFF position
pressure switch has not
before restarting. If bleeder valve does not open, replace
unloaded head pressure
bleeder valve.
Wrong wire gauge in cord
or excessive extension cord
Check for proper gauge and extension cord length.
length
Loose electrical
Contact authorized service center.
connections
Possible defective
Contact authorized service center.
capacitor
Paint spray on internal
Have checked at service center. Do not operate compressor in
motor arts
the paint spray area.
Possible defective motor
Contact authorized service center.
PARTS DIAGRAM
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PARTS LIST
Part
Description
Description
Qty
Qty Part
1
Screw M6x35
Quick Coupler
1
4 34
2
Spring Washer M6
Pressure Gauge
2
4 35
3
Nut M6
4 36
Quick Connect 90°
2
4
Cylinder Head
1 37
Pressure Switch
1
5
Exhaust Elbow
1 38
Regulator
1
6 Gasket Of Cylinder Head 1 39
Safety Valve
1
7
Valve Plate
1 40 Fixture Clab For Regulator 2
8
Valve
Screw St5x18
6
2 41
9
Aluminum Gasket
1 42
Pressure Tube
1
10 Gasket Of Cylinder Upper 1 43
Compression Nut G3/8
2
11
Cylinder
1 44
Brass Compression
2
12
Motor Set
1 45
Nylon Hose
1
13
Bearing 6001
1 46
Check Valve
1
14
Bearing 6201
1 47
Tank
1
15
Bearing 6203
1 48
Screw M6x20
2
16
Circlip Dia. 40
1 49
Screw M6x30
5
17
Eccentric
1 50
Washer M6
3
18
Belt
1 51
Spring Washer M6
3
19
Screw M6x16
1 52
Nut M6
3
20
Cover Of Conrod
1 53
Screw M5x12
8
21
Piston Ring
1 54
Rubber Foot
4
22
Conrod
1 55
Drain Valve
1
23
Screw M4x20
1 56
Handle
1
24
Spring Washer M4
1 57
Shroud
1
25
Nut M4
1 58
Tapping Screw St4x12
2
26
Round Fan
1 59
Press Fixture
1
27
Washer M5
1 60
Power Switch
1
28
Spring Washer M5
1 61
Power Cord
1
29
Screw M5x15
1 62
Cable Connector U
2
30
Motor Shroud
1 63
Cable Connector O
1
31
Screw St3.0x10
6 64
Inner Washer
2
32
Grounding Cable
1 65
Screw M4x6
2
33
Dual Connect Cord
1
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