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AirCompressor Table of Contents Topic Page Safety Guidelines - Definitions 4 Hazard Warnings 5 Air Compressor 15 • Precautions 15 • Basic Air Compressor Components 16 • Assembling the Compressor 16 • Compressor Controls 18 • Electrical Power Requirements 19 • Breaking In The Pump 21 • Operating Instructions 21 • Maintenance 23 • Storage 24 • Service 24 Troubleshooting 25 Glossary of Terms 29 Limited Warranty 3O 2
Owner'sManual WARNING! READ AND UNDERSTAND ALL SAFETY PRECAUTIONSIN THISMANUAL BEFORE OPERATING. FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS MANUAL COULD RESULT IN PERSONAL INJURY, PROPERTY DAMAGE, AND/OR VOIDING OF YOUR WARRANTY.ALL-POWERAMERICA WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THESEINSTRUCTIONS. Compressor Inspection Prior to installation and usage, thoroughly for damage or flaws.
AirCompressor Safety Guidelines- Definitions This manual contains important informationthat you need to know and understand in order to protect YOUR SAFETY and to PREVENT EQUIPMENT PROBLEMS. The following symbols help you recognize this information. Please read the manual and pay attention to these sections. POSSIBILITY OFPERSONALINJURYORDEATHIF INSTRUCTIONS WARNING!WARNINGSINDICATEA CERTAINTYORSTRONG ARE NOTFOLLOWED.
Owner'sManual Hazard Warnings Dust WARNING!SOMEDUSTCREATEDBYPOWERSANDING,SAWING, GRINDING, DRILLING,ANDOTHERCONSTRUCTION ACTIVITIES CONTAINSCHEMICALSKNOWNTOTHESTATEOFCALIFORNIATO CAUSECANCER,BIRTHDEFECTSOROTHERREPRODUCTIVE HARM.
AirCompressor HazardWarnings(cont'd) Riskof Eyeor HeadInjury What could happen: • Air powered equipment and power tools are capable of propelling materials such as fasteners, metal chips, saw dust, and other debris at high speed, which could resultin seriouseye injury. • Compressed air can be hazardous.The air stream can cause injuryto softtissue areas such as eyes, ears, etc. Particlesor objects propelledby the stream can cause injury.
Owner'sManual HazardWarnings(cont'd) Riskof Fireor Explosion What could happen: • Abrasive tools such as sanders and grinders, rotating tools such as drills, and impact tools such as nailers, staplers, wrenches, hammers, and reciprocating saws are capable of generating sparks which could result in ignition of flammable materials. • It is normal for the compressor motor and pressure switch to produce sparks while operating.
AirCompressor HazardWarnings(cont'd) Riskof HearingLoss What could happen: • Long term exposure to noise produced from the operation of air tools can lead to permanent hearing loss. How to prevent it: Always wear ANSI $3.19 hearing protection when using a compressor. HazardRiSk to Breathing/Inhalation What could happen: • • Abrasive tools such as grinders, sanders, and cut-off tools generate dust and abrasive materials which can be harmful to human lungs and respiratory system.
Owner'sManual HazardWarnings(cont'd) Riskof Injury What could happen: • Tools left unattended, or with the air hose attached can be activated by unauthorized persons leading to their injury and/or injury to others. • Air tools can propel fasteners or other materials throughout the work area. • A wrench or key that is left attached to a rotating part of the tool increases the risk of personal injury. • Using inflator nozzles for duster applications can cause serious injury.
AirCompressor HazardWarnings(cont'd) Riskof Injury(cont'd) How to prevent it: • Remove air hose when toolis not in use and store tool in secure location away from reach of children and or untrainedusers. • Use only parts, fasteners, and accessoriesrecommendedby the manufacturer. • Keep work area clean and free of clutter. Keep childrenand others away from work area during operationof the tool. • Keep work area well lit. • Remove adjustingkeys and wrenches before turningthe tool on.
Owner'sManual HazardWarnings(cont'd) Riskof Injury(cont'd) • Use only impact grade socketson an impact wrench. • Do not apply excessive force to the tool. Let the tool perform the work. • Never pointdischarge of tool at self or others. • Do not pulltrigger unlesstool contact safety device is against work surface. • Never attemptto drive fasteners into hard surfaces such as steel, concrete, or tile when using air tools. • Take care to avoid drivinga fastener on top of another fastener.
AirCompressor Hazard Warnings (cont'd) Riskof ElectricShock What could happen: • Using air tools to attach electrical electrocution or death. • Improper electrical connections fires,electrocution, or death. wiring can result in can result in This tool is not provided with an insulated gripping surface. Contact with a "live" wire makes exposed metal tool parts "live", resulting in possible electrocution or death.
Owner'sManual HazardWarnings(cont'd) Riskof Entanglement What could happen: • Tools containing moving elements or driving other moving tools (grinding wheels, sockets, sanding discs, etc.) can become entangled in hair, clothing, jewelry, and other loose objects, resulting in injury. How to prevent it: Never wear loose fitting clothes, or apparel whichcontains loose straps or ties, etc. which could become entangled in moving parts. Remove any jewelry, watches, identifications, bracelets, necklaces, etc.
AirCompressor HazardWarnings(cont'd) Riskof Cut or Burns What could happen: • Tools which cut, shear, drill, staple punch, chisel, etc. are capable of causing serious injury. • The pump and manifold generate high temperatures. How to prevent it: Keep the working part of the tool away from hands and body. • Do not touch the pump, manifold or transfer tube while the pump is running.Allowthem to cool before handling or servicing. • Keep children away from the compressor at all times.
Owner'sManual Compressor Item Value Model Number APC4016 Peak H.P. (CV) 3.5 Tank Capacity Gallons/Liters 6 Voltage/Amps/Phase 115/2.6/1 Kick-In Pressure 80 Kick-Out Pressure 100 WARNING! THE POWER CORD ON THIS PRODUCT CONTAINS LEAD, A CHEMICAL, KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCERAND BIRTH DEFECTS OR OTHER REPRODUCTIVEHARM. WASH HANDSAFTER HANDLING. Precautions • Drain the moisture from the tank daily to help prevent corrosion.
Owner'sManual Compressor(cont'd) BasicAir CompressorComponents The basic componentsof the air compressorare the electricmotor, pump, pressureswitch,and tank. The electric motor(see A) powersthe pump. The electric motoris equippedwith an overload protectorand an automatic reset. If the motorbecomes overheated, the overload protectorwill shut it downto preventdamage to the motor.When the motorsufficientlycools, it will automaticallyrestart.
AirCompressor m Compressor(cont'd) Assemblingthe Compressor(cont'd) Tighten the handle into its position with screws included. 2 Check the compressor's serial labelto ensure that you have received the model ordered, and that it has the required pressure rating for its intended use. 3 Locate the compressor accordingto the following guidelines: a Position the compressor near a grounded electrical outlet (see GROUNDING INSTRUCTIONS, above).
Owner'sManual Compressor(cont'd) CompressorControls • Power switch: This switchturns the compressorpower ON and OFF. • Pressure switch : This switch turnson the compressor. It is operated automaticallywhen the power switch is in the ON position,it allows the compressor to start up or shut down automatically,withoutwarning, depending upon air demand.
AirCom Compressor(cont'd) CompressorControls(cont'd) • Regulated pressure gauge: This gauge measures the regulated outlet pressure. • Regulated pressure quick connect coupler: This couplerconnects to the regulatedoutlet pressure.To connect air hose, pushcouplerin. To disconnectair hose, pull the couplercollar back and separate the coupling. ElectricalPowerRequirements ElectricalWiring Refer to the air compressor's serial label for the unit'svoltage and amperage requirements. Use a dedicated circuit.
Owner'sManual Compressor(cont'd) ElectricalPowerRequirements (cont'd) ExtensionCord Use the chart on the right for the proper extension cord length. Use only a 3-wire extension cord that has a 3-blade groundingplug, and a 3-slot receptaclethat willaccept the plug of the product. Make sure your extensioncord is in good condition. An undersizedcord will cause a drop in linevoltage as well as a lossof power and overheating.
AirCompressor Compressor (cont'd) Breaking Inthe Pump 1 Turn the pressure switch to the OFF position. 2 Open the petcock. Turn counterclockwise. 3 Plug in the power cord. 4 Turn the power switch to the ON position. The compressor will start. Allow the compressor to run for 15 minutes, to break in the internal parts. CAUTION: AFTER ABOUT 15 MINUTES. IF THE UNIT DOES NOT OPERATE PROPERLY, SHUT DOWN IMMEDIATELY, AND CONTACT PRODUCT SERVICE.
Owner'sManual Compressor(cont'd) OperatingInstructions(cont'd) _ 4 _ ELECTRICAL MOTOR AND THE PUMP. TO PREVENT BURNS OR ARNING! HIGH TEMPERATURESARE GENERATED BY THE OTHER INJURIES, DO NOT TOUCH THE COMPRESSOR WHILE IT IS RUNNING. ALLOW IT TO COOL BEFORE HANDLING OR SERVICING. KEEP CHILDRENAWAY FROM THE COMPRESSOR AT ALL TIMES. Turn the power switch to the ON position. PRESSURE,TURNTHEKNOBCOUNTERCLOCKWISE TOREACHTHE ARNING!WHENADJUSTINGFROMA HIGHERTOA LOWER DESIREDPRESSURE.
Air Corn Compressor(cont'd) Maintenance _ PLUGTHECOMPRESSOR ANDRELIEVEALLAIRPRESSURE FROMTHE WARNINGITOAVOIDPERSONALINJURY,ALWAYSSHUTOFFAND UNSYSTEMBEFOREPERFORMING ANYSERVICEONTHEAIR COMPRESSOR Regular maintenancewill ensure troublefree operation.Your electric powered air compressorrepresents high quality engineeringand construction;however, even high quality machinery requires periodic maintenance. Inspect the items listedbelow on a regularbasis.
Owner'sManual Compressor(cont'd) Maintenance(cont'd) Draining the Tank Relievetheair pressure inthesystemandopenthepetcock onthebottomofthetankto drain. WARNING! CONDENSATION WILLACCUMULATE IN THE TANK. TO PREVENT CORROSIONOF THE TANKFROM THE INSIDE, THIS MOISTURE MUST BE DRAINED AT THE END OF EVERY WORKDAY.BE SURE TO WEARPROTECTIVE EYEWEAR_ Note: In cold climates, drain the tank after each use to reduce problems with freezing of water condensation.
Air Troubleshooting solutions. Note: Troubleshooting problems may have similar causes and Lowpressure,or notenoughair,or compressordoesnotstop • Tank petcock is open ° Close petcock • Prolonged excessive use of air Decrease amountof air used • Compressornot large enough • o Check air requirement of accessory.If it is higherthan CFM and pressure supplied by compressor,you need a larger compressor. Most accessoriesare rated at 25% of actual CFM while running continuously.
Owner'sManual Troubleshooting(cont'd) Excessivestartingandstopping,whilenot in use • Fittings leak o Check fittings with soapy water. Tightenor reseal leaking fittings.DO NOT OVERTIGHTEN. Replace worn parts and reassemble with new seals. o Replace any faulty seals. • Air leaks from regulator,or regulator does not regulate pressure Dirty or damaged regulator internalparts. o, Replace regulatoror internalparts. • Regulatedpressure gauge readingdrops when air accessory is being used.
AirCompressor Troubleshooting(cont'd) Overheating • Poorventilation Relocate compressor to an area with cool, dry and well-circulatedair. • Dirtycoolingsurfaces o Clean all coolingsurfaces of pumpand motorthoroughly. • Leakingvalve Replace worn parts and reassemble with new seals. Motorstalls • Low voltage o Furnish adequate power.
Owner'sManual Troubleshooting(cont'd) Motorwill notrun(cont'd) • Fuse blown or circuit breaker tripped o Replace blownfuse or reset circuitbreaker. Do not use fuse or circuit breaker with higherrating than specifiedfor your branch circuit. o Check for properfuse; "Fusetron" type T is acceptable. o Check for low voltage and proper extensioncord size. o Disconnect other applicationsfrom circuit.Operate compressor on a dedicated circuit. • Check valve stuckopen o Remove and clean or replace.
Owner'sManual Glossary of Terms • CFM: Cubic feet per minute;a unit of measure of air flow. • PSh Pounds per square inch;a unitof measure of air pressure, • Kick-in pressure: Factoryset low pressure pointthat starts the compressorto repressurizethe tank to a higher pressure • Kick-out pressure: Factoryset high pressure pointthat stops the compressorfrom increasingthe pressure in the tank above a certain level.
Air Compressor LimitedWarranty ALL-POWER AMERICA warrants to the original purchaser who uses the product in a consumer application (personal, residential or household usage) that all products covered under this warranty are free from defects in material and workmanship for one year from the date of purchase. All products covered by this limited warranty which are used in commercial applications (i.e.
Owner'sManual LimitedWarranty (cont'd) THIS WARRANTY DOES NOT COVER: Merchandise sold as reconditioned, display models.
Air Compressor LimitedWarranty (cont'd) ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECTS, FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT COVERED BY THIS WARRANTY. Some states do not allow the exclusion, so it may not apply to you. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY OR SUITABILITY FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM THE DATE OF ORIGINAL PURCHASE.
