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Oil Lube Two StageAir Compressor

Instructionmanual

IMPORTANTPlease make certain that the personwho is to use this equipment carefullyreads and understands theseinstructions before starting operations.

Part No. D27042-045-0

ESPAÑOL: PÁGINA 27FRANÇAIS: PAGE 53

To learn more about Porter-Cable visit our website at:

http://www.porter-cable.com

Copyright © 2004 Porter-Cable Corporation

The Model and Serial No. plate is located on the frame.Record these numbers in the spaces below and retain forfuture reference.

Model No.

Type

Serial No.

MODEL C7550

2-ENGD27042

SAFETY GUIDELINES - DEFINITIONS

Indicates an imminentlyhazardous situation

which, if not avoided, will result in deathor serious injury.

Indicates a potentiallyhazardous situation

which, if not avoided, could result indeath or serious injury.

Indicates a potentiallyhazardous situation

which, if not avoided, may result inminor or moderate injury.

Used without thesafety alert symbol

indicates a potentially hazardoussituation which, if not avoided, mayresult in property damage.

This manual contains information that is important for you to know andunderstand. This information relates to protecting YOUR SAFETY andPREVENTING EQUIPMENT PROBLEMS. To help you recognize thisinformation, we use the symbols below. Please read the manual and payattention to these symbols.

IMPORTANT SAFETY INSTRUCTIONSSome dust created by power sanding, sawing, grinding,drilling, and other construction activities contains chemicals

known (to the State of California) to cause cancer, birth defects or otherreproductive harm. Some example of these chemicals are:● lead from lead-based paints● crystalline silica from bricks and cement and other masonry products● arsenic and chromium from chemically-treated lumberYour risk from these exposures varies, depending on how often you do thistype of work. To reduce your exposure to these chemicals: work in a wellventilated area, and work with approved safety equipment, always wearMSHA/NIOSH approved, properly fitting face mask or respirator when usingsuch tools.When using air tools, basic safety precautions should always be followed toreduce the risk of of personal injury.

3-ENG D27042

IMPORTANT SAFETY INSTRUCTIONS

Save these instructions

Improper operation or maintenance of this product could result in serious injury andproperty damage. Read and understand all warnings and operation instructions beforeusing this equipment.

HAZARD

WARNING: Risk of explosion or fire

How To Prevent ItWhat Could Happen

It is normal for electrical contactswithin the motor and pressure switch tospark.

If electrical sparks from compressorcome into contact with flammablevapors, they may ignite, causing fire orexplosion.

Restricting any of the compressorventilation openings will cause seriousoverheating and could cause fire.

Unattended operation of this productcould result in personal injury orproperty damage. To reduce the risk offire, do not allow the compressor tooperate unattended.

Always operate the compressor in a wellventilated area free of combustiblematerials, gasoline, or solvent vapors.

If spraying flammable materials, locatecompressor at least 20 feet away fromspray area. An additional length of hosemay be required.Store flammable materials in a securelocation away from compressor.

Never place objects against or on topof compressor. Operate compressor inan open area at least 12 inches awayfrom any wall or obstruction that wouldrestrict the flow of fresh air to theventilation openings.Operate compressor in a clean, dry wellventilated area. Do not operate unitindoors or in any confined area.

Always remain in attendance with theproduct when it is operating.Always disconnect electrical power bymoving pressure switch lever to the offposition and drain tank daily or aftereach use.

4-ENGD27042

WARNING: Risk of Bursting

Air Tank: The following conditions could lead to a weakening of the tank, and resultin a violent tank explosion and could cause property damage or serious injury.


WARNING: Risk from Flying Objects

The compressed air stream can causesoft tissue damage to exposed skinand can propel dirt, chips, looseparticles, and small objects at highspeed, resulting in property damage orpersonal injury.

Always wear ANSI Z87.1 approved safetyglasses with side shields when using thecompressor.

Never point any nozzle or sprayertoward any part of the body or at otherpeople or animals.

Always turn the compressor off andbleed pressure from the air hose and tankbefore attempting maintenance, attachingtools or accessories.

HAZARD

HAZARD

Drain tank daily or after each use. Iftank develops a leak, replace itimmediately with a new tank or replacethe entire compressor.

Failure to properly drain condensedwater from tank, causing rust andthinning of the steel tank.

Modifications or attempted repairs to the tank.

Unauthorized modifications to the unloader valve, safety valve, or any other components which control tank pressure.

Never drill into, weld, or make anymodifications to the tank or itsattachments.

Excessive vibration can weaken the air tank and cause rupture or explosion

The tank is designed to withstand specificoperating pressures. Never makeadjustments or parts substitutions toalter the factory set operatingpressures.

For essential control of air pressure, youmust install a pressure regulator andpressure gauge to the air outlet (if notequipped) of your compressor. Follow theequipment manufacturersrecommendation and never exceed themaximum allowable pressure rating ofattachments. Never use compressor toinflate small low pressure objects suchas children’s toys, footballs,basketballs, etc.

ATTACHMENTS & ACCESSORIES:Exceeding the pressure rating of airtools, spray guns, air operatedaccessories, tires, and other inflatablescan cause them to explode or fly apart,and could result in serious injury.


5-ENG D27042

WARNING: Risk to Breathing

WARNING: Risk of Electrical Shock

HAZARD

HAZARD

Your air compressor is powered byelectricity. Like any other electricallypowered device, If it is not usedproperly it may cause electric shock.

Repairs attempted by unqualifiedpersonnel can result in serious injuryor death by electrocution.

Electrical Grounding: Failure to provideadequate grounding to this productcould result in serious injury or deathfrom electrocution. See grounding instructions.

Never operate the compressor outdoorswhen it is raining or in wet conditions.Never operate compressor withprotective covers removed or damaged.

Any electrical wiring or repairs requiredon this product should be performed byauthorized service center personnel inaccordance with national and localelectrical codes.

Make certain that the electrical circuit towhich the compressor is connectedprovides proper electrical grounding,correct voltage and adequate fuseprotection.

The compressed air directly from yourcompressor is not safe for breathing.The air stream may contain carbonmonoxide, toxic vapors, or solidparticles from the tank. Breathing thesecontaminants can cause serious injuryor death.

Sprayed materials such as paint, paintsolvents, paint remover, insecticides,weed killers, may contain harmfulvapors and poisons.

Air obtained directly from the compressorshould never be used to supply air forhuman consumption. In order to use airproduced by this compressor forbreathing, suitable filters and in-linesafety equipment must be properlyinstalled. In-line filters and safetyequipment used in conjunction with thecompressor must be capable of treatingair to all applicable local and federalcodes prior to human consumption.

Work in an area with good crossventilation. Read and follow the safetyinstructions provided on the label orsafety data sheets for the materials youare spraying. Use a NIOSH/ MSHAapproved respirator designed for use withyour specific application.



6-ENGD27042

WARNING: Risk of Burns

Touching exposed metal such as thecompressor head or outlet tubes, canresult in serious burns.

Never touch any exposed metal partson compressor during or immediatelyafter operation. Compressor will remainhot for several minutes after operation.Do not reach around protective shroudsor attempt maintenance until unit hasbeen allowed to cool.

WARNING: Risk from Moving Parts

Never operate the compressor withguards or covers which are damaged orremoved.

Moving parts such as the pulley, flywheel,and belt can cause serious injury if theycome into contact with you or yourclothing.

WARNING: Risk of Falling

A portable compressor can fall from atable, workbench, or roof causingdamage to the compressor and couldresult in serious injury or death to theoperator.

Always operate compressor in a stablesecure position to prevent accidentalmovement of the unit. Never operatecompressor on a roof or other elevatedposition. Use additional air hose toreach high locations.

HAZARD

HAZARD

HAZARD

Any repairs required on this productshould be performed by authorizedservice center personnel.

Attempting to operate compressor withdamaged or missing parts or attemptingto repair compressor with protectiveshrouds removed can expose you tomoving parts and can result in seriousinjury.




7-ENG D27042

Review and understand all instructionsand warnings in this manual.Become familiar with the operation andcontrols of the air compressor.Keep operating area clear of all persons,pets, and obstacles.Keep children away from the aircompressor at all times.Do not operate the product whenfatigued or under the influence ofalcohol or drugs. Stay alert at all times.Never defeat the safety features of thisproduct.Equip area of operation with a fireextinguisher.Do not operate machine with missing,broken, or unauthorized parts.

WARNING: Risk of Unsafe Operation

Unsafe operation of your air compressorcould lead to serious injury or death toyou or others.

HAZARD

WARNING: Risk of Serious Injury or Property Damage WhenTransporting Compressor

Oil can leak or spill and could result infire or breathing hazard; serious injury ordeath can result. oil leaks will damagecarpet, paint or other surfaces invehicles or trailers.

Always place COMPRESSOR on aprotective mat when transporting toprotect against damage to vehicle fromleaks. Remove COMPRESSOR fromvehicle immediately upon arrival at yourdestination.

(Fire, Inhalation, Damage to Vehicle Surfaces)

HAZARD

SAVE THESE INSTRUCTIONS



8-ENGD27042

Model No. C7550Horsepower Peak 7.0Voltage-Single Phase 240VMinimum Branch Circuit Requirement 30 amps*Fuse Type Time DelayAir Tank Capacity, Gallons 80 ASME, VerticalApproximate Cut-in Pressure 140 PSIGApproximate Cut-out Pressure 175 PSIGSCFM @ 100 psig 15.6SCFM @ 175 psig 15.2

GLOSSARY

DUTY CYCLE

Accessories for this unit are available at the store the unit was purchased.

ACCESSORIES

Become familiar with these termsbefore operating the unit.CFM: Cubic feet per minute.SCFM: Standard cubic feet perminute; a unit of measure of airdelivery.PSIG: Pounds per square inch gauge;a unit of measure of pressure.Code Certification: Products thatbear one or more of the followingmarks: UL, CUL, ETL, CETL, havebeen evaluated by OSHA certifiedindependent safety laboratories andmeet the applicable UnderwritersLaboratories Standards for Safety.Cut-In Pressure: While the motor isoff, air tank pressure drops as youcontinue to use your accessory.When the tank pressure drops to acertain low level the motor will restart

automatically. The low pressure atwhich the motor automaticallyrestarts is called "cut-in" pressure.Cut-Out Pressure: When an aircompressor is turned on and beginsto run, air pressure in the air tankbegins to build. It builds to a certainhigh pressure before the motorautomatically shuts off - protectingyour air tank from pressure higherthan its capacity. The high pressureat which the motor shuts off is called"cut-out" pressure.Branch Circuit: Circuit carryingelectricity from electrical panel tooutlet.To Lock Out Power: Place a lock onthe line power switch so no one elsecan turn on the power.

This air compressor pump is capableof running continuously. However, toprolong the life of your aircompressor, it is recommended that a

50%-75% average duty cycle bemaintained; that is, the air compressorpump should not run more than 30-45minutes in any given hour.

SPECIFICATIONS

Multi-Viscositymotor oils, like 10W

30, should not be used in an aircompressor. They leave carbondeposits on critical components,thus reducing performance andcompressor life. Use aircompressor oil only.NOTE: Oil is included with someunits. If oil is not included, use an oilspecifically formulated for use in anair compressor, such as Porter-CablePAS1 air compressor oil. Oil may befound at the store where the aircompressor was purchased.1. Place unit on a level surface.

Drain tank torelease air pressure

before removing the oil fill cap or oildrain plug.2. Remove oil fill plug (A) and slowly

add a compressor oil to themiddle of sight glass (B). NOTE:When filling the crankcase, the oilflows very slowly into the pump.If the oil is added too quickly, itwill overflow and appear to befull. NOTE: Crankcase oilcapacity is approximately 48 fluidounces.

3. Replace oil fill plug.

A

B

9-ENG D27042

ASSEMBLY

Tools Required for Assembly1 - 9/16" socket or open end wrench

1 - Electric drill

Unpacking1. Remove all packaging.

It may benecessary to brace

or support one side of the outfitwhen removing the pallet becausethe air compressor will have atendency to tip.2. Remove and discard the (4)

screws and washers holding thecompressor to the pallet.

3. With the help of another personcarefully remove air compressorfrom pallet and place on a levelsurface.

Contents of Carton1 - Air Compressor1 - Parts bag containing:

1 - Operator’s Manual1 - Parts Manual4 - 5/8" Washers

To Add Oil To PumpCompressors areshipped with some

oil due to factory testing. Do notoperate this air compressorwithout adding the correct amountof oil to the pump crankcase.Serious damage can result fromeven the minimal operation if thepump crankcase does not containthe correct amount of oil. Makesure the break-in procedure iscompleted before operating the aircompressor.

10-ENGD27042

1. Place the air compressor on asolid, level surface.

2. Mark the surface using the holesin the air compressor feet as atemplate.

3. Drill holes in the surface for theconcrete anchors. Installconcrete anchors.

4. Line-up holes in surface withholes in air compressor feet.

5. Place the (4) washers (supplied)between the floor and aircompressor feet. If needed, solidshims may be placed betweenthe washers and floor to evenlydistribute weight on all four feet.See next figure.

6. Place the (4) 3/8" lag screwsthrough the air compressor feet,washers, shims, and into theanchors.

7. Torque 3/8" lag screws to 7-10ft.-lbs.

INSTALLATIONHOW TO SET UP YOUR UNITLocation of the Air Compressor• Locate the air compressor in a

clean, dry, and well ventilatedarea.

• Located the air compressor atleast 12" away from the wall orother obstructions that willinterfere with the flow of air.

• Locate the air compressor asclose to the main power supplyas possible to avoid using longlengths of electrical wiring.NOTE: Long lengths of electricalwiring could cause power loss tothe motor.

• The air filter must be kept clearof obstructions which couldreduce air flow to the aircompressor.

Anchoring of the AirCompressor

Risk of Bursting.Excessive Vibration

can weaken the air tank and causean explosion. The compressormust be properly mounted.The air compressor MUST be boltedto a solid, level surface.Hardware needed:

4 - Concrete anchors (notsupplied)

4 - 3/8" Lag screw to fitconcrete anchors (not supplied)

4 - 5/8" Washer (supplied)shims (if needed)

3/8" LagScrew (not supplied)

5/8" Washer(supplied)

Shim UnderWasher(not supplied)

Concrete Anchor(not supplied)

Surface Line

11-ENG D27042

Voltage and Circuit ProtectionRefer to the specification chart for thevoltage and minimum branch circuitrequirements.

GROUNDINGINSTRUCTIONSThis product should be connected toa metallic, permanent wiring system,of an equipment-grounding terminalor lead on the product.

Wiring InstructionsRisk of ElectricalShock. Improper

electrical grounding can result inelectrical shock. The wiring shouldbe done by a qualified electricianA qualified electrician needs to knowsthe following before wiring:1. The amperage rating of the

electrical box should beadequate. Refer to theSpecification Chart, in the partsmanual, for this information.

2. The supply line should have thesame electrical characteristics(voltage, cycle, phase) as themotor. Refer to the motornameplate, on side of motor, forthis information.

NOTE: The wiring must be the sameas the motor nameplate voltage plusor minus 10%. Refer to local codesfor recommended wire sizes, correctwire size, and maximum wire run;undersize wire causes high amp drawand overheating to the motor.

Risk of ElectricalShock. Electrical

wiring must be located away fromhot surfaces such as manifoldassembly, compressor outlet tubes,heads, or cylinders.

12-ENGD27042

Air Distribution SystemRisk of Bursting.Plastic or PVC pipe

is not designed for use withcompressed air. Regardless of itsindicated pressure rating, plasticpipe can burst from air pressure.Use only metal pipe for airdistribution lines.The next figure represents a typicalair distribution system. The followingare tips to remember when setting upthe air compressor’s air distributionsystem.

● Use pipe that is the same size asthe air tank outlet. Piping that istoo small will restrict the flow ofair.

● If piping is over 100 feet long,use the next larger size.

● Bury underground lines belowthe frost line and avoid pocketswhere condensation can gatherand freeze. Apply pressurebefore underground lines arecovered to make sure all pipejoints are free of leaks.

● A flexible coupling isrecommended to be installedbetween the air discharge outletand main air distribution line toallow for vibration.

● A separate regulator isrecommended to control the airpressure. Air pressure from thetank is usually to high forindividual air driven tools.

DRAINTRAP

DRAINTRAPS

DRAINLEGS

MOISTURESEPARATORAND TRAP

DIRTLEG

DIRTLEG

LUBRICATOR

REGULATOR

FILTER

AIR DISCHARGEVALVE

LUBRICATOR

MAIN DISTRIBUTION AIR LINESSlope pipe in direction of air flow.Water condensate flows along bottom of pipe to drain legs, preventing it from entering feeder lines.

REGULATOR

FLEXIBLECOUPLING

DRAIN COCKVALVE

TYPICAL COMPRESSEDAIR DISTRIBUTION SYSTEM

AIR FLOWAIR FLOW

FEEDER LINES SLOPEWITH AIR FLOW

AIR USAGELINES

AIRCOMPRESSOR

13-ENG D27042

Globe Valve

TankPressureGauge

Safety Valve

On/Auto/OffSwitch

Pressure Switch

Tank Pressure Gauge: The tankpressure gauge indicates the reserveair pressure in the tank. Globe Valve (sold separately):Opens and closes air discharge valve.Turn knob counter-clockwise to openand clockwise to close.

Regulator (sold separately, notshown): An air pressure regulator ora separate air transformer whichcombines the functions of airregulation and/or moisture and dirtremoval is recommended for mostapplications.

Cooling System (not shown): Thiscompressor contains an advanceddesign cooling system. At the heartof this cooling system is anengineered fan. It is perfectly normalfor this fan to blow air through thevent holes in large amounts. Youknow that the cooling system isworking when air is being expelled.

Description of OperationBecome familiar with these controlsbefore operating the unit.On/Auto/Off Lever: Turn this switch"On/Auto" to provide automaticpower to the pressure switch and"Off" to remove power at the end ofeach use.Pressure Switch: The pressureswitch automatically starts the motorwhen the air tank pressure dropsbelow the factory set "cut-in"pressure. It stops the motor when theair tank pressure reaches the factoryset "cut-out" pressure.Safety Valve: If the pressure switchdoes not shut off the air compressorat its "cut-out" pressure setting, thesafety valve will protect against highpressure by "popping out" at itsfactory set pressure (slightly higherthan the pressure switch "cut-out"setting).

OPERATION

Know Your Air Compressor

READ THIS OWNER’S MANUAL AND SAFETY RULES BEFORE OPERATINGYOUR UNIT. Compare the illustrations with your unit to familiarize yourself withthe location of various controls and adjustments. Save this manual for futurereference.

14-ENGD27042

Air Compressor Pump (not shown):Compresses air into the air tank.Working air is not available until thecompressor has raised the air tankpressure above that required at theair outlet.Drain Valve: Thedrain valve islocated at thebase of the airtank and is usedto drain condensation at the end ofeach use.Check Valve: When the aircompressor is operating, the checkvalve is "open", allowing compressedair to enter the air tank. When the aircompressor reaches "cut-out"pressure, the check valve "closes",allowing air pressure to remain insidethe air tank.

Pressure Release Valve: Thepressure release valve located on theside of the pressure switch, isdesigned to automatically releasecompressed air from the compressorhead and the outlet tube when the aircompressor reaches "cut-out"pressure or is shut off. The pressurerelease valve allows the motor torestart freely. When the motor stopsrunning, air will be heard escapingfrom this valve for a few seconds.No air should be heard leaking whenthe motor is running or after the unitreaches "cut-out" pressure.

Motor Overload Protector: Thismotor has a manual thermal overloadprotector. If the motor overheats forany reason, the overload protectorwill shut off the motor. The motormust be allowed to cool down beforerestarting. To restart:1. Place the On/Auto/Off lever in

the "Off" position.

2. Allow the motor to cool.

3. Depress the red reset button onthe motor.

4. Place theOn/Auto/Offlever in the"On/Auto"postion torestart themotor.

Air Intake Filter (not shown): Thisfilter is designed to clean air cominginto the pump. This filter must alwaysbe clean and ventilation openingsfree from obstructions. See"Maintenance".

ResetButton

Drain Valve

Check Valve

PressureReleaseValve

How to Use Your UnitHow to Stop:

1. Set the On/Auto/Off lever to"Off".

Before Starting

Break-in ProcedureRisk of UnsafeOperation. Serious

damage may result if the followingbreak-in instructions are not closely followed.This procedure is required before theair compressor is put into service andwhen the check valve or a completecompressor pump has beenreplaced.1. Make sure the On/Auto/Off lever

is in the "Off" position.

15-ENG D27042

2. Check oil level in pump. See"Oil" paragraph in the"Maintenance" section forinstructions.

3. Recheck all wiring. Make surewires are secure at all terminalsconnections. Make sure allcontacts move freely and are notobstructed.

4. Open the globe valve fully topermit air to escape and preventair pressure build up in the airtank during the break-in period.

5. Move the On/Auto/Off lever to"On/Auto" position. Thecompressor will start.

6. Run the compressor for 20minutes. Make sure the globevalve is open and there isminimal air pressure build-up intank.

7. Check all air line fittings andconnections/piping for air leaksby applying a soap solution.Correct if necessary. NOTE:Minor leaks can cause the aircompressor to overwork,resulting in premature breakdownor inadequate performance.

8. Check for excessive vibration.Readjust or shim air compressorfeet, if necessary.

9. After 20 minutes, close the globevalve. The air receiver will fill to"cut-out" pressure and the motorwill stop.

Before Each Start-Up:1. Place On/Auto/Off lever to "Off".

2. Close the globe valve.

3. Attach hose and accessories.NOTE: A regulator MUST beinstalled when using accessoriesrated at less than 175 PSI.

NOTE: The hose or accessory willrequire a quick connect plug if the airoutlet is equipped with a quickconnect socket.

Risk of Bursting. Toomuch air pressure

causes a hazardous risk ofbursting. Check the manufacturer’smaximum pressure rating for airtools and accessories. Theregulator outlet pressure mustnever exceed the maximumpressure rating.

How to Start:

1. Turn the On/Auto/Off lever to"On/Auto" and allow tankpressure to build. Motor willstop when tank pressure reaches"cut-out" pressure.

2. When the tank pressure reaches"cut-out" pressure open theglobe valve.

IMPORTANT: When using regulatorand other accessories refer to themanufacturers instructions.

The compressor is ready for use.

16-ENGD27042

MAINTENANCECustomer Responsibilities

Daily oraftereachuse

Beforeeachuse

●

●●

●

Every8hours

Every40hours

Every100hours

YearlyEvery160hours

●

●1

1- more frequent in dusty or humid conditions

Check Safety Valve

Drain Tank

Oil Leaks

Check OilChange Oil

Air Filter

NOTE: See "Operation" section for the location of controls.

To Check Safety ValveRisk of Bursting. Ifthe safety valve

does not work properly, over-pressurization may occur, causingair tank rupture or an explosion.

Unusual Noise and/orVibration

Drive Belt-Condition

Motor Pulley/Flywheel alignment

Air compressor pump intakeand exhaust valvesInspect air lines and fittingsfor leaks

●

●

●

●

●

Head Bolts - Check the torques of the head bolts after the first five hours of operation.

1. Before starting compressor, pullthe ring on the safety valve tomake sure that the safety valveoperates freely. If the valve isstuck or does not operatesmoothly, it must be replacedwith the same type of valve.

To ensure efficient operation and longer life of the air compressor, a routinemaintenance schedule should be prepared and followed. The above routinemaintenance schedule is geared to an air compressor in a normal workingenvironment operating on a daily basis. If necessary, the schedule should bemodified to suit the conditions under which your air compressor is used. Themodifications will depend upon the hours of operation and the workingenvironment. Compressors in an extremely dirty and/or hostile environment willrequire a greater frequency of all maintenance checks.

Risk of Unsafe Operation. Unit cycles automatically whenpower is on. When servicing, you may be exposed to

voltage sources, compressed air, or moving parts. Before servicing unitunplug or disconnect electrical supply to the air compressor, bleed tankof pressure, and allow the air compressor to cool.

17-ENG D27042

To Drain TankNOTE: Operation of the aircompressor will cause condensationto build up in the air tank. Alwaysdrain tank on a washable surface orin a suitable container to preventdamaging or staining surfaces.1. Set the On/Auto/Off lever to

"Off".2. Close the globe valve.3. Remove the air tool or accessory.4. Open the globe valve and allow

the air to slowly bleed from theair tank until tank pressure isapproximately 20 psi.

5. Close the globe valve.6. Drain water from

air tank by openingdrain valve onbottom of tank.

Riskof

Bursting. Water will condense inthe air tank. If not drained, waterwill corrode and weaken the airtank causing a risk of air tankrupture.7. After the water has

been drained,close the drainvalve. The aircompressor cannow be stored.

NOTE: If drain valve isplugged, release all air pressure. Thevalve can then be removed, cleaned,then reinstalled.

Open DrainValve

Closed DrainValve

Checking1. The oil level should be to the

middle of the sight glass (C).2. If needed remove oil fill plug (A)

and slowly add oil until it reachesthe middle of the sight glass.

Changing1. Remove the oil fill plug (A). 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. Sowly add compressor oil until

the oil level is in the middle ofthe sightglass (C). NOTE: Whenfilling the crankcase, the oil flowsvery slowly into the pump. If theoil is added too quickly, it willoverflow and appear to be full.

Risk of UnsafeOperation.

Overfilling with oil will causepremature compressor failure. Donot overfill.5. Replace oil fill plug (A) and

tighten securely.OilNOTE: Use an oil specificallyformulated for use in an aircompressor, such as Porter-CablePAS1 air compressor oil. Oil may befound at the store where the aircompressor was purchased.NOTE: Crankcase oil capacity isapproximately 48 fluid ounces (1.4 L).

C

B

A

18-ENGD27042

Air Filter - Inspection andReplacement

Hot surfaces. Riskof burn.

Compressor heads are exposedwhen filter cover is removed.Allow compressor to cool prior toservicing.

Keep the air filterclean at all times.

Do not operate the air compressorwith the air filter removed.A dirty air filter will not allow thecompressor to operate at fullcapacity. Keep the air filter clean atall times. 1. Remove air filter.2. Remove the air filter cover.3. Remove the air filter from filter

cover.IMPORTANT: Do not operate thecompressor with the air filterremoved.4. Place new air filter into filter

cover. Refer to the "RepairParts" for the correct partnumber.

5. Replace air filter cover andreassemble air filter to pump.

Belt - Replacement(Refer to the Parts Manual forreplacement belt part number.)

Serious injury ordamage may

occur if parts of the body or looseitems get caught in moving parts.Never operate the outfit with thebelt guard removed. The beltguard should be removed onlywhen the air compressor power isdisconnected.1. Turn air compressor off, lock out

the power supply, and relieve allair pressure from the air tank.

2. Remove the belt guard.3. Mark pump position on saddle.

4. Loosen the motor mountingscrews and slide the motortoward the air compressor.

5. Remove the belt and replacewith a new one.

6. See the "Adjust Belt Tension"before tightening motor mountingscrews.

Adjusting Belt Tension1. Slide motor into original position,

line the motor up with the markmade earlier on saddle.

2. Tighten two outside motormounting screws enough to holdthe motor in place for checkingpulley and flywheel alignment.

3. The belt should deflect 3/16" atmidway between the pulley andthe flywheel when a 5-10 poundweight is applied at the midwaypoint.

3. When proper belt tension isachieved, tighten all four motormounting screws. See Partsmanual for torque specifications.

NOTE: Once the engine pulley hasbeen moved from its factory setlocation, the grooves of theflywheel and pulley must bealigned to within 1/16" to preventexcessive belt wear. Verify thealignment by performing thefollowing Pulley and Flywheel -Alignment.

Downward Force

Deflection

19-ENG D27042

Air Compressor PumpIntake and Exhaust ValvesOnce a year have a Trained ServiceTechnician check the air compressorpump intake and exhaust valves.

Inspect Air Lines andFittings for Leaks1. Turn air compressor off, lock out


2. Apply a soap solution to all airline fittings andconnections/piping.

3. Correct any leaks found.

IMPORTANT: Even minor leaks cancause the air compressor tooverwork, resulting in prematurebreakdown or inadequateperformance.

Motor Pulley/FlywheelAlignmentNOTE: Once the motor pulley hasbeen moved from its factory setlocation, the grooves of the flywheeland pulley must be aligned to within1/16" to prevent excessive belt wear.The air compressor flywheel andmotor pulley must be in-line (in thesame plane) within 1/16" to assurebelt retention within flywheel beltgrooves. To check alignment,perform the following steps:1. Turn air compressor off, lock out


2. Remove belt guard.3. Place a straightedge against the

outside of the flywheel and themotor drive pulley.

4. Measure the distance betweenthe edge of the belt and thestraightedge at points A1 and A2in figure. The difference betweenmeasurements should be nomore than 1/16".

5. If the difference is greater than1/16" loosen the set screwholding the motor drive pulley tothe shaft and adjust the pulley’sposition on the shaft until the A1and A2 measurements are within1/16" of each other.

6. Tighten the motor drive pulley setscrew. See Parts manual fortorque specifications.

Air compressor Head Bolts -Torquing The air compressor pump head boltsshould be kept properly torqued.Check the torques of the head boltsafter the first five hours of operation.Retighten if necessary. See Partsmanual for torque specifications.

7. Visually inspect the motor drivepulley to verify that it isperpendicular to the drive motorshaft. Points B1 and B2 of Figureshould appear to be equal. Ifthey are not, loosen the setscrewof the motor drive pulley andequalize B1 and B2, using carenot to disturb the belt alignmentperformed in step 2.

8. Retighten the motor drive pulleysetscrew. See Parts manual fortorque specifications.

9. Reinstall belt guard.

20-ENGD27042

7. Clean or replace the check valve.A solvent, such as paint orvarnish remover can be used toclean the check valve.

8. Apply sealant to the check valvethreads. Reinstall the check valve(turn clockwise).

9. Replace the pressure releasetube. Tighten nuts.

10. Replace the outlet tube andtighten nuts.

11. Perform the Break-in Procedure.See "Break-in Procedure" in theOperation section.

To Replace or Clean CheckValve 1. Release all air pressure from air

tank. See "To Drain Tank" in theMaintenance section.

2. Turn air compressor off, lock outthe power supply, and relieve allair pressure from the air tank.

3. Using an adjustable wrenchloosen outlet tube nut at air tankand pump. Carefully move outlettube away from check valve.

4. Using an adjustable wrenchloosen pressure relief tube nut atair tank and pressure switch.Carefully move pressure relieftube away from check valve.

5. Unscrew the check valve (turncounterclockwise) using a 7/8"open end wrench. Note theorientation for reassembly.

6. Using a screwdriver, carefullypush the valve disc up anddown. NOTE: The valve discshould move freely up and downon a spring which holds the valvedisc in the closed position, if notthe check valve needs to becleaned or replaced.

In closed positiondisc is visible.

In openpositionnothing isvisible.

Screwdriver

SERVICE AND ADJUSTMENTS

Risk of Unsafe Operation. Unit cycles automatically whenpower is on. When servicing, you may be exposed to

voltage sources, compressed air, or moving parts. Before servicing unitunplug or disconnect electrical supply to the air compressor, bleed tank ofpressure, and allow the air compressor to cool.

ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BEPERFORMED BY TRAINED SERVICE TECHNICIAN.

Additional ServiceDisassembly or service of the aircompressor beyond what is coveredin this manual is not recommended. Ifadditional service is required, contactyour nearest Authorized WarrantyService Center.

21-ENG D27042

STORAGE

Before you store the air compressor,make sure you do the following:

1. Review the "Maintenance"section on the preceding pagesand perform scheduledmaintenance as necessary.

2. Set the On/Auto/Off lever to"Off".

3. Close the globe valve.

4. Remove the air tool or accessory.

5. Open the globe valve and allowthe air to slowly bleed from theair tank until tank pressure isapproximately 20 psi.

6. Drain water from air tank byopening drain valve on bottom oftank.

Water willcondense in the air

tank. If not drained, water willcorrode and weaken the air tankcausing a risk of air tank rupture.7. After the water has been drained,

close the drain or drain valve.

NOTE: If drain valve is plugged,release all air pressure. The valvecan then be removed, cleaned, thenreinstalled.

8. Protect the air hose fromdamage (such as being steppedon or run over).

22-ENGD27042

TROUBLESHOOTINGPerforming repairs may expose voltage sources, movingparts or compressed air sources. Personal injury may

occur. Prior to attempting any repairs, unplug the air compressor andbleed off all air tank air pressure.

PROBLEM CAUSE CORRECTION

Pressure switch does notshut off motor whencompressor reaches "cut-out" pressure.

Pressure switch "cut-out"too high.

Move On/Auto/Off lever tothe "Off" position, if the unitdoes not shut off contact aTrained Service Technician. Contact a Trained ServiceTechnician.

Excessive tankpressure -safety valvepops off.

Tube fittings are not tightenough.

Tighten fittings where air canbe heard escaping. Checkfittings with soapy watersolution. DO NOT OVERTIGHTEN.

Air leaks atfittings.

Air leaks atpressure switchrelease valve.

Defective pressure switchrelease valve.

Contact a Trained ServiceTechnician.

Air leaks in airtank or at airtank welds.

Defective air tank. Air tank must be replaced.Do not repair the leak.

Do not drillinto, weld

or otherwise modify airtank or it will weaken. Thetank can rupture orexplode.

Air leaksbetween headand valve plate.

Leaking seal. Contact a Trained ServiceTechnician.

Air leaks at orinside checkvalve.

Check valve seat damaged. A defective check valveresults in a constant air leakat the pressure release valvewhen there is pressure in thetank and the compressor isshut off. Replace checkvalve. Refer the "To Replaceor Clean Check Valve" in the"Service and Adjustments"section.

23-ENG D27042


Compressor isnot supplyingenough air tooperateaccessories.

Prolonged excessive use ofair.Compressor is not largeenough for air requirement.

Hole in hose.

Check valve restricted.

Air leaks.

Restricted air intake filter.

Decrease amount of air usage.

Check the accessory airrequirement. If it is higher thanthe SCFM or pressure suppliedby your air compressor, youneed a larger compressor.Check and replace if required.

Remove and clean, or replace.

Tighten fittings.

Clean or replace air intakefilter. Do not operate the aircompressor with the filterremoved. Refer to the "AirFilter" paragraph in the"Maintenance " section.

Pressure readingon the regulatedpressure gauge(if equipped)drops when anaccessory isused.

It is normal for "some"pressure drop to occur.

If there is an excessive amountof pressure drop when theaccessory is used, adjust theregulator as instructed in theOperation section.NOTE: Adjust the regulatedpressure under flow conditions(while accessory is beingused).

Possible defect in safetyvalve.

Operate safety valve manuallyby pulling on ring. If valve stillleaks, it should be replaced.

Air leak fromsafety valve.

Clean or replace. See Air Filterparagraph in the Maintenancesection.

Dirty air filter.Restricted airintake.

Loose belt. Check belt tension, seeAdjusting Belt Tension in theMaintenance section.

24-ENGD27042

PROBLEM CAUSE CORRECTIONMotor will notrun.

Fuse blown, circuit breakertripped.

1. Check fuse box for blownfuse and replace asnecessary. Reset circuitbreaker. Do not use a fuseor circuit breaker withhigher rating than thatspecified for yourparticular branch circuit.

2. Check for proper fuse. Youshould use a time delayfuse.

3. Check for low voltageconditions and/or properextension cord.

4. Disconnect the otherelectrical appliances fromcircuit or operate thecompressor on its ownbranch circuit.

Motor overload protectionswitch has tripped.

Let motor cool off andoverload switch willautomatically reset.

Tank pressure exceedspressure switch "cut-in"pressure.

Motor will start automaticallywhen tank pressure dropsbelow "cut-in" pressure ofpressure switch.

Loose electricalconnections.

Check wiring connectioninside pressure switch andterminal box area.

Have checked by a TrainedService Technician.

Check valve stuck open. Remove and clean, or replace.

Possible defective motoror starting capacitor.

Have checked by a TrainedService Technician. Do notoperate the compressor in thepaint spray area. Seeflammable vapor warning.

Paint spray on internalmotor parts.

Bleed the line by pushing thelever on the pressure switch tothe "Off" position; if the valvedoes not open, replace switch.

Pressure release valve onpressure switch has notunloaded head pressure.

Pressure switch, checkvalve, or pump could bein need of servicing.

Safety Valve onpump "pops"out (ifequipped).

Have checked by a TrainedService Technician.

25-ENG D27042


Knocking Noise. Possible defect in safetyvalve.

Operate safety valve manuallyby pulling on ring. If valve stillleaks, it should be replaced.

Loose pulley. Tighten pulley set screw, seeParts manual for torquespecifications.

Compressor mountingscrews loose.

Tighten mounting screws,seeParts manual for torquespecifications.

Loose flywheel. Tighten flywheel screw, seeParts manual for torquespecifications.

Loose belt. Check belt tension, seeAdjusting Belt Tension in theMaintenance section.

Carbon build-up in pump. Have checked by a TrainedService Technician.

Belt to tight. Check belt tension, seeAdjusting Belt Tension in theMaintenance section.

Excessive beltwear.

Loose belt.

Tight belt.

Loose pulley. Have checked by a TrainedService Technician.

Pulley misalignment. See Motor Pulley/FlywheelAlignment paragraph in theMaintenance section.

Squealingsound.

Loose belt.

Compressor pump has nooil.

See Oil-Checking paragraph inthe Maintenance section.

Check belt tension, seeAdjusting Belt Tension in theMaintenance section.



Defective check valve. Remove and clean, or replace.

26-ENGD27042

LIMITED WARRANTYPORTER-CABLE CORPORATION warrants to the original purchaser that all products covered under thiswarranty are free from defects in material and workmanship. Products covered under this warranty include aircompressors, air tools, service parts, pressure washers, and generators, which have the following warrantyperiods:

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 residentialhousehold 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 failedwithin the warranty period. Service will be scheduled according to the normal work flow and businesshours 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 tostate.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

evaluated 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

nearest Porter-Cable Authorized Warranty Service Center that provides on-site service calls, for servicecall arrangements.

• If the purchaser does not receive satisfactory results from the Porter-Cable Authorized Warranty ServiceCenter, 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 operatethe product in accordance with the instructions provided in the Owners Manual(s) supplied with theproduct, 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 the recommended duty cycle during a one hour period maybe considered misuse.

• 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 andshear 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 ofanother company, such as gasoline engines. The product manufacturer's warranty, if any, will apply.

• ANY INCIDENTAL, INDIRECT OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAYRESULT FROM ANY DEFECT, FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT COVERED BYTHIS WARRANTY. Some states do not allow the exclusion or limitation of incidental or consequentialdamages, so the above limitation or exclusion may not apply to you.

• IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY OR FITNESS FOR APARTICULAR 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 maynot apply to you.

Porter-Cable CorporationJackson, TN USA1-888-559-8550

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