SAFETY GUIDELINES - DEFINITIONS
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Safety is a combination of common sense, staying alert and knowing how your compressor works.
Read this manual to understand this compressor.
IMPORTANT SAFETY 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
Only persons familiar with these rules of safe operation should use the air compressor.
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. 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).
Inspect your work area
1. Keep work area clean.
2. Cluttered areas and benches invite accidents. Floors
Inspect your compressor
1. To reduce the risk of injury from accidental starting, turn switch off and disconnect the power before checking it.
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.
3. Check hoses for weak or worn condition before each use, making certain all connections are secure. Do Not use if defect is found
Do not operate compressor if damaged during shipping, handling or use. Damage may result in bursting and cause injury or property damage
This compressor is Not designed for and should not be used in breathing air applications.
When installing or moving the compressor
WARNING : This compressor is extremely top heavy. The compressor must be secured to the floor before operating to prevent equipment damage, injury or death. The compressor must be mounted on vibration pads. 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.
2. Operate compressor in a well-ventilated area free from flammable liquids and vapors.
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.
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.
WARNING : Do Not secure compressor with toggle bolts into drywall. Drywall sheeting or plaster will not support the weight of the compressor
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.
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.
WARNING : Never use plastic (PVC) pipe for compressed air. Serious injury or death could result
CAUTION : Never use the shipping skid for mounting the compressor
NOTICE : This compressor is not intended for outdoor installation
WARNING : Never install a shut off valve between the compressor pump and tank. Personal injury and/or equipment damage could occur
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
Follow the safety precautions for electrical connections
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.
3. Protect wires from contact with sharp objects.
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.
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 : Be careful when touching the exterior of compressor, pump, motor and air lines; they may become hot enough to cause injury.
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.
IMPORTANT SAFETY 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
Only persons familiar with these rules of safe operation should use the air compressor.
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. 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).
Inspect your work area
1. Keep work area clean.
2. Cluttered areas and benches invite accidents. Floors
Inspect your compressor
1. To reduce the risk of injury from accidental starting, turn switch off and disconnect the power before checking it.
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.
3. Check hoses for weak or worn condition before each use, making certain all connections are secure. Do Not use if defect is found
Do not operate compressor if damaged during shipping, handling or use. Damage may result in bursting and cause injury or property damage
This compressor is Not designed for and should not be used in breathing air applications.
When installing or moving the compressor
WARNING : This compressor is extremely top heavy. The compressor must be secured to the floor before operating to prevent equipment damage, injury or death. The compressor must be mounted on vibration pads. 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.
2. Operate compressor in a well-ventilated area free from flammable liquids and vapors.
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.
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.
WARNING : Do Not secure compressor with toggle bolts into drywall. Drywall sheeting or plaster will not support the weight of the compressor
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.
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.
WARNING : Never use plastic (PVC) pipe for compressed air. Serious injury or death could result
CAUTION : Never use the shipping skid for mounting the compressor
NOTICE : This compressor is not intended for outdoor installation
WARNING : Never install a shut off valve between the compressor pump and tank. Personal injury and/or equipment damage could occur
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
Follow the safety precautions for electrical connections
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.
3. Protect wires from contact with sharp objects.
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.
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 : Be careful when touching the exterior of compressor, pump, motor and air lines; they may become hot enough to cause injury.
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.
TYPICAL COMPRESSOR INSTALLATION
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GLOSSARY OF TERMS
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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
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.
Pressure Switch
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)
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.
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.
lectrical equipment with an approved cleaning agent, such as a dry, non-flam- mable cleaning solvent.
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.
Daily
Check oil level at sight glass. Oil level should be 1/2 to slightly higher in the 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. Tighten any necessary part.
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 non-detergent oil should be used. Part # 82-6020
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
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.
Pressure Switch
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)
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.
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.
lectrical equipment with an approved cleaning agent, such as a dry, non-flam- mable cleaning solvent.
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.
Daily
Check oil level at sight glass. Oil level should be 1/2 to slightly higher in the 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. Tighten any necessary part.
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 non-detergent oil should be used. Part # 82-6020
WIRING
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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. Size supply wiring per NEC (National Electric Code) requirements.
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.
CAUTION : Overheating, short circuiting and fire damage will result from inadequate wiring
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. Size supply wiring per NEC (National Electric Code) requirements.
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.
CAUTION : Overheating, short circuiting and fire damage will result from inadequate wiring
STARTING THE COMPRESSOR
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Prior to running the compressor, check
the following items:
Crankcase oil - Make sure the sight glass shows ½ full or slightly above.
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.
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. (175 PSI Max)
CAUTION : Make sure the pressure in the tank does not exceed its rating. Maximum of 175 psi. If the pressure gauge indicates a pressure that is higher than these maximum pressures, shut off compressor immediately and call 866-869-3114.
(Gas Drive Models)
PLEASE REFER TO YOUR ENGINE OPERATION MANUAL FOR PROPER STARTING INSTRUCTIONS.
NAPA GASOLINE DRIVEN COMPRESSORS ARE EQUIPPED WITH A COLD START VALVE FOR LOADLESS STARTS. THERE IS NO NEED TO MANUALLY UNLOAD AIR PRESSURE
Battery Connection Instructions for Electric Start Engines
Note:Make sure to follow instructions carefully to avoid a short and possible damage to the starter solenoid and/or battery.
1. Connect the positive (+) terminal on the battery to the starter solenoid.
2. Connect the negative (-) terminal on the battery to an engine mounting bolt or other acceptable ground connection.
Always connect the positive(+) battery cable to the starter solenoid before connecting the negative(-) battery cable.
QP Compressors
The QP comes equipped with sound attenuating enclosure. For maintenance, the canopy and side foam pieces will need to be removed.
QP and Fully Packaged Compressors
QP and fully packaged models come equipped with low oil level switches and automatic tank drains. The QP models also include protection against over-heating.
Low Oil Level Switch
The function of the low oil level switch is to keep the air compressor from starting if the oil level drops beyond a certain point.
For compressors outfitted with the low oil level switch, the oil should in the top 1/3 of the oil sight glass.
When changing or adding oil, it is important to remove the Oil Vent Plug to allow for the oil to flow completely into the switch.
(Please Note: If overfilled, oil will flow out of the oil vent hole)
Thermal Protection - QP Models
If the cooling fan were to fail or internal temperature were to reach 170°F the QP models are outfitted with a thermal fuse.
When tripped, the fuse can be reset. The canopy will need to be removed to reset the thermal fuse.
Crankcase oil - Make sure the sight glass shows ½ full or slightly above.
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.
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. (175 PSI Max)
CAUTION : Make sure the pressure in the tank does not exceed its rating. Maximum of 175 psi. If the pressure gauge indicates a pressure that is higher than these maximum pressures, shut off compressor immediately and call 866-869-3114.
(Gas Drive Models)
PLEASE REFER TO YOUR ENGINE OPERATION MANUAL FOR PROPER STARTING INSTRUCTIONS.
NAPA GASOLINE DRIVEN COMPRESSORS ARE EQUIPPED WITH A COLD START VALVE FOR LOADLESS STARTS. THERE IS NO NEED TO MANUALLY UNLOAD AIR PRESSURE
Battery Connection Instructions for Electric Start Engines
Note:Make sure to follow instructions carefully to avoid a short and possible damage to the starter solenoid and/or battery.
1. Connect the positive (+) terminal on the battery to the starter solenoid.
2. Connect the negative (-) terminal on the battery to an engine mounting bolt or other acceptable ground connection.
Always connect the positive(+) battery cable to the starter solenoid before connecting the negative(-) battery cable.
QP Compressors
The QP comes equipped with sound attenuating enclosure. For maintenance, the canopy and side foam pieces will need to be removed.
QP and Fully Packaged Compressors
QP and fully packaged models come equipped with low oil level switches and automatic tank drains. The QP models also include protection against over-heating.
Low Oil Level Switch
The function of the low oil level switch is to keep the air compressor from starting if the oil level drops beyond a certain point.
For compressors outfitted with the low oil level switch, the oil should in the top 1/3 of the oil sight glass.
When changing or adding oil, it is important to remove the Oil Vent Plug to allow for the oil to flow completely into the switch.
(Please Note: If overfilled, oil will flow out of the oil vent hole)
Thermal Protection - QP Models
If the cooling fan were to fail or internal temperature were to reach 170°F the QP models are outfitted with a thermal fuse.
When tripped, the fuse can be reset. The canopy will need to be removed to reset the thermal fuse.
TROUBLESHOOTING GUIDE
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