Air Compressor Manual

Pt# 1312100710

Models: 824252PAT

824253PAT

824256VAT

824276VAT

Service and Support: 866-869-3114

Rev0411

TABLE OF CONTENTS

PAGE

1 Safety Guidelines - Definitions

Before Using the Air Compressor

2 When Installing or Moving the Compressor

Before Each Use

3 Follow Safety Precautions for Electrical Connection

Plan Ahead to Protect Your Eyes, Hands, Face & Ears

When Operating

4 Spraying Precautions

Perform These Maintenance Operations

5 Warning Labels

Glossary

6 Wiring

Starting the Compressor

7-8 Troubleshooting

9-11 Parts

12 Warranty Statement

SAFETY GUIDELINES - DEFINITIONS

Safety is a combination of common sense, staying alert and knowing how your compressor works.

Read this manual to understand this compressor.

DANGER

means if safety information is not followed someone will be seriously injured or killed

WARNING

means if safety information is not followed someone could be seriously injured or killed

CAUTION

means if safety information is not followed someone may be seriously injured or killed

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 compressor.

Before using the air compressor

Things you should know

Air compressors are utilized in a variety of air system applications. Because air compressors and other components (hoses, connectors, air tools, spray guns, etc.) make up a high pressure pumping system, the following safety precautions should be observed at all times.

Inspect your work area

1. Keep work area clean.

2. Cluttered areas and benches invite accidents.

Floors must not be slippery from wax or dust.

Inspect your compressor

Only persons familiar with these rules of safe operation should use the air compressor.

1. To reduce the risk of injury from accidental

starting, turn switch off and disconnect the

power before checking it.

1. Read the instruction manual carefully before

attempting to assemble, disassemble or

operate your system. Be thoroughly familiar

with the controls and the proper use of the

equipment.

2. If any part is missing, bent or broken in any

way, or any electrical part does not work prop-

erly, keep the compressor off and disconnected.

2. Review and understand all safety instructions

and operating procedures in this manual.

3. Review the maintenance methods for this

compressor (See “Maintaining Your

Compressor” section).

3. Check hoses for weak or worn condition

before each use, making certain all connections

are secure. Do Not use if defect is found.

WARNING

Do not operate compressor if damaged during shipping, handling or use. Damage may result in bursting and cause injury or property damage.

DANGER

This compressor is Not designed for and should not be used in breathing air applications.

Page 1

When installing or moving the compressor

WARNING

This compressor is extremely top heavy. The compressor must be bolted to the floor with vibration pads before operating to prevent equipment damage, injury or death. Do Not tighten bolts completely as this may cause stress to the tank welds.

To reduce the risk of a dangerous environment

1. Keep work area well lit.

6. A minimum clearance of 18 inches between

the compressor and a wall is required

because objects could obstruct airflow.

7. The compressor should be located where it can

be directly wired to a circuit breaker. The

compressor should be wired by a qualified

electrician.

8. Never store flammable liquids or gases in

the vicinity of an operating compressor.

2. Operate compressor in a well-ventilated

area free from flammable liquids and vapors.

9. Do Not locate the compressor air inlet near

steam, paint spray, sandblasting areas or

any other source of contamination. The

debris could damage the motor and pump.

3. Operate compressor in a ventilated area so

that compressor may be properly cooled and

the surrounding air temperature will not be

more than 100°F.

WARNING

Never use plastic (PVC) pipe for compressed air. Serious injury or death could result.

4. Never use a compressor in a wet

environment.

5. Protect material lines and air lines from

damage or puncture. Keep hose and

wires away from sharp objects, chemical

spills, oil, solvents and wet floors.

CAUTION

Never use the shipping skid for mounting the compressor.

NOTICE

WARNING This compressor is not intended for outdoor installation.

Do Not secure compressor with toggle bolts into drywall. Drywall sheeting or plaster will not support the weight of the compressor.

WARNING

Never install a shut off valve between the compressor pump and tank. Personal injury and/or equipment damage could occur.

Note: Tank Outlet Size: 1/4” NPT for Models 824252PAT & 824253PAT

½” NPT for Models 824256VAT & 824276VAT

Before each use

Inspect your work area

1. Keep work area clean. Cluttered areas and

benches invite accidents.

2. The floor must not be slippery from wax or

dust.

Inspect your compressor

1. To reduce the risk of injury from accidental

starting, turn the switch off and disconnect

power.

2. If any part is missing, bent or broken in any

way, or any electrical part does not work

properly, keep the compressor off and dis-

connect power. Do Not use if defect is found.

3. Check hoses for weak or worn condition

before each use, making certain all connect-

ions are secure. Do Not use if a defect is

found.

Page 2

Follow the safety precautions for electrical connections

3. Protect wires from contact with sharp objects.

1. Follow all local electrical and safety codes,

as well as the National Electric Code (NEC)

and the Occupational Safety and Health

Act (OSHA).

2. Wiring and fuses should follow electrical

codes, current capacity and be properly

grounded.

CAUTION

All electrical connections should be made by a qualified electrician.

Plan ahead to protect your eyes, hands, face and ears

Dress for safety

1. Wear safety glasses (meeting ANSI Z87.1 or

in Canada CSA Z94.3-99) and use hearing

protection when operating the unit. Everyday

glasses are not safety glasses.

WARNING

Be careful when touching the exterior of compressor, pump, motor and air lines; they may become hot enough to cause injury.

2. Wear shoes to prevent shock hazards.

3. Tie back long hair.

Pay attention to your hands

WARNING

Keep fingers away from running compressor.

Fast moving and hot parts may cause injury and/or burns.

WARNING

Never operate the compressor without a beltguard. The compressor can start automatically without warning. Personal injury or property damage could occur from contact with moving parts.

CAUTION

The compressor may be hot even if the unit is stopped.

WARNING

Use of a mask or respirator per chemical manufacturers’ instructions may be necessary if there is a chance of inhaling toxic fumes.

Read mask and respirator instructions carefully. Consult a safety expert if you are not sure about the use of certain masks or respirators.

When operating

1. Do not exceed the pressure rating of any

component of the system.

2. Release pressure within the system slowly

to prevent flying dust and debris.

3. If the equipment starts to abnormally vibrate,

STOP the compressor immediately and

check for the cause.

WARNING

Never change the safety valve or pressure switch settings. Keep safety valve free from paint and other accumulations. See compressor specification decal for maximum operating pressure. Do not operate with the pressure switch set higher than the maximum operating pressure.

Page 3

Spraying precautions

WARNING

Never point a spray gun at yourself or any other person or animal. Accidental discharge may result in serious injury.

Reduce the risk of dangerous environment

WARNING

Extreme caution should be taken when spraying flammable liquids as the spark from a motor or pressure switch may cause a fire or explosion. Ample ventilation must be provided.

WARNING

Spray in a well ventilated area to keep fumes from collecting and causing serious injury and fire hazards.

1. Do Not spray in the vicinity of open flames

or other places where a spark can cause

ignition. Do Not smoke when spraying

paint, insecticides, or other flammable

substances.

Be informed about the materials you use

1. When spraying with solvents or toxic chemi-

cals, follow the instructions provided by the

chemical manufacturer. Consult a safety

expert if unsure about the use of masks or

respirators.

2. If the material you intend to spray contains

trichloreoethane and methylene chloride, do

not use accessories that contain aluminum or

galvanized materials, as these chemicals can

react with galvanized components causing

corrosion and weakening equipment. Use

stainless steel accessories.

Perform these maintenance operations

1. Do regular maintenance; keep all nuts, bolts,

and screws tight, to be sure equipment is in

safe working condition.

2. Inspect tank yearly for rust, pin holes or any

other imperfections that could cause it to

become unsafe.

WARNING

NEVER attempt to repair or modify a tank!

Welding, drilling or any other modification will weaken the tank resulting in damage from rupture or explosion. Always replace worn, cracked or damaged tanks.

3. Clean electrical equipment with an approved

cleaning agent, such as a dry, non-flam-

mable cleaning solvent.

Daily

Check oil level at sight glass. Oil should be

1/2 way to slightly above in oil sight glass.

Drain moisture from tank.

Verify the pressure switch unloader is working by listening for a brief hissing sound when the compressor shuts off.

Visually check the compressor for loose parts, excessive noise or vibration.

4. Drain tanks of moisture after each day’s use.

If unit will not be used for awhile, it is best to

leave the drain cock open until such time as it

is to be used. This will allow moisture to

completely drain out and help prevent

corrosion of inside of tank.

5. Always disconnect from power source before

working on or near a motor, or its connected

load. If power disconnect point is out-of-

sight, secure it in the “OFF” position and tag it

to prevent unexpected application of power.

WARNING

Disconnect power and depressurize system before servicing air compressor. Slightly open drain cock after shutting off compressor.

Monthly

(Make sure the main power is off.) Check the belts for tension. Belts should not move up and down when the compressor runs and when stopped, should not have more than ½ in of play when depressed. Be careful not to over tighten belts during adjustment.

Remove and check air filter, replace if necessary.

Change oil every 3 months or 300 hours. A compressor grade 40 wt. non-detergent oil should be used.

Page 4

WARNING LABELS

WIRING

Find and read all warning labels found on the air compressor.

Sample Warning Labels shown.

Your decals may vary.

GLOSSARY OF TERMS

Pressure Switch Air Filter

Porous element contained within a metal or plastic housing attached to the compressor cylinder head which removes impurity from the intake air of the compressor.

Air Tank

Device which 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)

Cylindrical component which contains the compressed air.

Check Valve

Device which prevents compressed air from flowing back from the air tank to the compressor pump.

Electric Motor

Device which provides the rotational force necessary to operate the compressor pump.

Pressure Gauge

Device which shows the tank or regulated pressure of the compressed air.

Measurement of the pressure exerted by the force of air. The actual psi is measured by a pressure gauge on the compressor.

Pump

Device which produces the compressed air with a reciprocating piston contained within a cylinder.

Safety Valve

Device which prevents air pressure in the air tank from rising over a predetermined limit.

Thermal Overload Switch

Device, integrated into the electric motor winding, which automatically “shuts off” the compressor if the temperature of the electric motor exceeds a predetermined limit.

Page 5

WARNING

ALL ELECTRICAL WIRING SHOULD BE DONE

BY A QUALIFIED ELECTRICIAN

General Information

Adequate wiring and motor protection should be provided for all stationary compressors. Wiring used for other machinery should not be used. A qualified electrician familiar with local electrical codes in your area should be used.

Incoming power should be connected to the posts marked (LINE)

Do Not Make

Connections On

Prewired Posts

Marked (MOTOR)!

WARNING

To reduce the risk of electrical hazards, fire hazards or damage to the compressor, use proper circuit protection. Your compressor is wired at the factory for operation using the voltage shown. Connect the compressor to a power source with the correct breaker size.

WARNING

Electrical connections must be properly grounded. Ground connections should be connected at the grounding screw.

Model

824252PAT

824253PAT

824256VAT

Voltage

FLA

Breaker Size

115V / 1 ph

15

20 amp

CAUTION

Overheating, short circuiting and fire damage will result from inadequate wiring.

82476VAT

208-230V / 1 ph

16

30 amp

Electrical connections must be properly grounded. Ground connections should be connected at a grounding screw.

The motor is equipped with a manual, resetable overload device to protect it from overheating. In the event the compressor will not run and power is properly connected and on, press the motor overload reset button located on the non drive end of the motor.

STARTING THE COMPRESSOR

STARTING THE COMPRESSOR

Prior to actually running the compressor, check the following items:

Crankcase oil - Make sure the sight glass shows ½ full or slightly above.

Operate the compressor for a few minutes unloaded (air system open) then allow the compressor to pump up. Make sure the electrical pressure switch properly switches off the compressor according to the setting desired.

Make sure all rags, tools, oil, etc. are away from the unit.

Open the air system to free it of any pressure.

Switch the compressor on for a few revolutions to make sure the rotation is correct. Correct rotation is clockwise when facing the sight glass on the pump.

CAUTION

Make sure the pressure in the tank does not exceed its rating. Single stage compressors should operate at a maximum of

135 psi. If the pressure gauge indicates a pressure thatis higher than these maximum pressures, shut off compressor immediately and call 1-866-869-3114.

Page 6

TROUBLESHOOTING GUIDE

Low discharge pressure 1. Compressor too small for

application

Excessive noise

“knocking”

Excessive oil carryover

2. Air leaks

3. Restricted intake air

4. Blown gasket(s)

5. Broken or misaligned valves

1. Loose drive pulley or flywheel

2. Low on oil

3. Worn connecting rod or

connecting rod bearing

4. Noisy check valve

1. Worn piston rings

2. Restricted intake air

3. Too much oil in compressor

4. Incorrect oil viscosity

1. Reduce air demand or use a compressor

with more air capacity.

2. Listen for air leaks. Apply a soap solution

to all fittings and connections. Bubbles

will form at points of leakage. Tighten

or replace fittings or connections.

3. Clean or replace air filter.

4. Replace necessary gaskets.

5. Remove head and inspect for broken or

misaligned valves. Replace valves, if

necessary.

Install a new head gasket

!

CAUTION

1. Tighten drive pulley or flywheel bolt.

2. Check for proper oil level. Low or dirty

oil may cause bearing damage.

3. Replace connecting rod and/or connecting

rod bearings.

4. Replace check valve.

Do not remove check valve DANGER

1. Replace with new piston rings.

2. Clean or replace air filter.

3. Drain oil to proper oil level.

4. Use a quality non-detergent 30 or 40wt

oil specified for each model (Page 4).

Water in tank and/or discharge line

Will not run or motor hums

Breaker or reset repeatedly trips

Tank does not hold pressure when not running and shut off valve is closed

1. Normal. Amount of water will

increase as humidity in the

air increases.

1. Drain tank at least once per day.

2. Add an inline filter to reduce moisture in

in the air line.

1. Low voltage

2. Malfunctioning pressure switch

3. Malfunctioning check valve

1. Check voltage with volt meter across both

legs of incoming power. Check reset button

on motor.

2. Repair or replace pressure switch.

3. Replace check valve or pressure switch.

DANGER Do not remove check valve

1. Incorrect breaker size

2. Low voltage

3. Malfunctioning motor

4. Loose electrical connections

5. Malfunctioning pressure switch

6. Malfunctioning check valve

1. Make sure the breaker is sized properly.

See page 6 in this manual.

2. Check voltage with volt meter across both

legs of incoming power.

3. Replace motor.

4. Check all electrical connections.

5. Adjust or replace pressure switch.

6. Replace check valve.

Do not remove check valve

DANGER

1. Malfunctioning check valve

2. Loose fittings or connections

3. Crack or pin hole in tank

1. Replace check valve.

DANGER Do not remove check valve

2. Tighten or replace fittings or connections.

3. Replace tank. Do not attempt to repair tank.

Page 7

TROUBLESHOOTING GUIDE (Continued)

Pressure switch unloader constantly leaking air

Pressure switch not unloading

1. Malfunctioning check valve

1. Malfunctioning pressure

switch

Excessive vibration

Overheating

1. Improper installation

2. Loose belts

3. Misaligned flywheel or

drive pulley

1. Compressor too small for

application

2. Cooling surfaces dirty

3. Improper cooling

1. Replace check valve if unloader bleeds

constantly.

Do not remove check valve

!

DANGER

1. Replace pressure switch if it does not release

air pressure briefly when unit shuts off.

Do not remove pressure

DANGER

tank

1. Make sure unit is mounted on a level surface

with vibration pads.

2. Replace belts. Align and tighten properly.

3. Align flywheel and drive pulley.

1. Reduce air demand or use a compressor

with more air capacity.

2. Clean all cooling surfaces of dirt and dust.

3. Install compressor in an area with adequate

cool dry air.

Page 8

Pump 82-1312100119

Handle

82-2236107285

Regulator

82-1312100002

Pressure Switch

82-1312100455

824252PAT

Drive Pulley

Safety Valve

Gauge

Belt

82-1312100440

82-1312100005

82-1312100006

82-1312100129

Check Valve 82-1312100168

Unloader Line 82-1312100026

Pump

82-1312100119

Beltguard

82-6214343100 &

82-2236110472

Regulator

82-1312100002

Beltguard

82-6214343100 & 82-2236110472

Motor

82-1312100388

Discharge Tube

82-1312100213

Tank

82-1312100474

Drain

82-1312100360

Wheel

82-1312100060

Discharge Tube

82-1312100213

Motor

82-1312100388

Pressure Switch

82-1312100455

Handle

82-2236107294

Tank

82-1312100476

824253PAT

Drive Pulley

Safety Valve

Gauge

Belt

82-1312100440

82-1312100005

82-1312100006

82-1312100129

Check Valve 82-1312100168

Unloader Line 82-1312100026

Wheel

82-1312100029

Drain

82-1312100360

08

06

02

01

09

03

10

04

05

1. Compressor

2. Air Filter

3. Electric Motor

4. Safety Valve

5. Pressure Switch

6. Pressure Gauge

7. Tank Drain

8. Check Valve

9. Discharge Tube

10. Belt Guard

11. Unloader Line

(Not Visible)

12. Drive Belt

(Not Visible)

13. Drive Pulley

(Not Visible)

07

824256VAT

82-1312100119

82-2236102108

82-1312100388

82-1312100005

82-1312100455

82-1312100006

82-1312100360

82-1312100168

82-1312100216

82-6214343100 (Front)

82-2236110472 (Back)

82-1312100026

82-1312100129

82-1312100440

Page 9

824276VAT

82-1312100123

82-2236102108

82-1312100390

82-1312100005

82-1312100455

82-1312100006

82-1312100360

82-1312100168

82-1312100215

82-6214343100 (Front)

82-2236110472 (Back)

82-1312100026

82-1312100134

82-1312100448

11

09

07

05

01

10

02

12

08

Page 10

06

03

04

Compressor Pump

82-1312100119

01 Valve Assembly Kit

02 Conrod Kit

03 Crankshaft Kit

04 Crankcase Bottom Kit

05 Cylinder Kit

06 Shaft Seal Kit

07 Head Kit

08 Flywheel Kit

09 Top Gasket Kit

10 Oil Level Kit

11 Air Filter Kit

12 Ring Kit (2 Required)

Compressor Pump

82-1312100123

01 Valve Assembly Kit

02 Conrod Kit

03 Crankshaft Kit

04 Crankcase Bottom Kit

05 Cylinder Kit

06 Shaft Seal Kit

07 Head Kit

08 Flywheel Kit

09 Top Gasket Kit

10 Oil Level Kit

11 Air Filter Kit

12 Ring Kit (2 Required)

82-6229024900

82-9428010

82-9428020

82-6229022500

82-6229022900

82-9428050

82-6229023900

82-6229023400

82-6229023600

82-9428100-KIT

82-6229020500

82-9428120

82-6229024900

82-6229021800

82-6229022800

82-9428031

82-6229023100

82-9428050

82-6229023900

82-9428071

82-6229023600

82-9428100-KIT

82-6229020500

82-9428120

Page 11

AIR COMPRESSOR WARRANTY POLICY

Atlas Copco Compressors, LLC makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for a period of one year from date of purchase.

(90 days if used by a professional contractor or if used as rental equipment).

This warranty does not apply to damage due directly or indirectly to misuse, abuse, negligence or accidents; repairs or alterations outside our facilities; or lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement.

We will return the repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

Altas Copco Compressors, LLC

1800 Overview Drive

Rock Hill, SC 29730

Service and Support: 866-869-3114