AC205 - 4 Gallon Hand Carry Compressor Brochure

operation manualAC2052table of contentsIntroduction4 Using the Operators ManualSpecifications4 SpecificationsProduct Identification5 Record Identification NumbersSafety6 Safety Instructions7 Safety Rules7 Hazard Symbols and Meanings10 General Safety Information11 Spraying Precautions11 Hose PrecautionsInstallation and Grounding12 Installation and Location13 Extension CordsAssembly Instructions14 AssemblyProduct Features15 Automatic ON/OFF15 Regulator15 Tank Pressure Gauge15 Safety Valve15 Tank Drain Fitting15 Thermal Shutdown Switch3table of contentsOperating Instructions16 Initial Start Up16 Start Up16 Storage16 Shut DownMaintenance17 When performing any maintenance or service17 Daily17 Weekly17 Monthly17 Six Months or 250 Operating Hours17 Oil ChangeParts18 AC205 Parts Diagram19 AC205 Parts List4Using the Operator’s manualThank you for choosing our compressor. The manual gives information with respect to operation and maintenance of the AC205 Compressor and be sure to read it carefully first before operation.Following the manual can ensure the user’s safety and get the best results from the compressor. All information and diagrams in this manual are in accordance with the newest products at the publishing time. We strive for accuracy and this manual is accurate for the models described at the time of printing. We reserve the right to make improvements or changes at any time without notice or obligation.Please keep this manual with the engine permanently, even if the engine ownership is transferred.Attention: Read through the complete manual prior to the initial use of your compressor.introductionSpecifications· 4 Gallon Twin Tank Design· Oil Lubricated for Extended Durability· 3450 Rpm Induction Motor for Long Life· 120V, 60Hz, 12.4Amps· Air Delivery: 4.2CFM output @ 40 PSI and 3.5 CFM output @90 PSI· Maximum Pressure: 125 PSI· Thermal Overload Protection for safety· High Flow regulator and Dual Pressure Gauges for Precision Air Flow Control· Control Panel, Two quick Connect Couplersspecifications5product identificationRecord Identification NumbersCompressorIf you need to contact an Authorized Dealer or Customer Service line (1-866-850-6662) for information on servicing, always provide the product model and identification numbers.You will need to locate the model and serial number for the machine and record the information in the places provided below. Date of Purchase:Dealer Name:Dealer Phone:Product Identification NumbersModel Number:Serial Number:6safetySafety Instructions· Carefully read through the entire owners manual before operating this compressor. · Keep manual with important records for safety instructions, operating procedures and warranty.· After unpacking your new air compressor, please inspect it carefully for any damage that may have occurred during transit. · Do not operate this air compressor if damaged during shipment, handling or misuse.· Damage may result in bursting, which can cause serious injury or property damage. · All damaged parts must be repaired or replaced as needed prior to operating this air compressor.· Check to see that all nuts, bolts and fittings are secure. · Check to see that the proper lubrication oil, which has been included with the air compressor, is used to fill the compressor crankcase to the proper level.· Please contact our customer service department at the numbers listed on the back of this instruction manual for any questions or comments regarding this air compressor.7The safety alert symbol ( ) is used with a signal word (DANGER, CAUTION, WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard which, if not avoided, will result in death or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury. CAUTION indicates a hazard which, if not avoided, might result in minor or moderate injury. NOTICE indicates a situation that could result in equipment damage.Follow safety messages to avoid or reduce the risk of injury ordeath.Hazard Symbols and MeaningsSave these InstructionsSafety RulessafetyThis is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.explosionkickbackfall fluid injection moving parts read manualhot surface wear eye protectionslipperyfire electric shock toxic fumes8safetyWARNINGAIR TANK WARNING: Drain liquid from air tank daily, or after each use, using the drain valve located on the bottom of the lower air tank. Failure to properly drain liquid from the tank will cause rust from moisture build-up, which weakens the tank and could lead to a violent tank explosion, Periodically inspect the tanks for unsafe conditions such as corrosion.Never attempt to repair or make modifications to the tank or its at-tachments. Welding, drilling or any other modifications may weaken the tank, which may result in damage from rupture or explosion. Never remove or attempt to adjust the pressure switch, safety valve, or other factory set operating pressures.WARNINGFIRE WARNING: Avoid dangerous environments. Do not use compressor near gasoline or other flammable materials. Keep work area well lit. Normal sparking of a motor or sparking from grinding metal could ignite fumes. Do not spray flammable materials in the vicinity of an open flame or other ignition source, including the air compressor itself. Do not direct paint or other spray material towards the compressor.Read and follow all safely instructions for the material you are spray-ing. Be sure to use an approved respirator designed for use with your specific application.WARNINGBREATHABLE AIR WARNING: This air compressor in not designed, nor intended for the supply of breathable quality air. Air produced by this unit may contain carbon monoxide or other toxic vapors. Do not inhale air from the compressor or from a breathing device con-nected to it.9safetyWARNINGELECTRIC SHOCK WARNING: When using electric powered tools, machines or equipment, basic safety precautions should always be followed to minimize the risk of electrical shock or personal injury to yourself and others. This air compressor is powered by electricity and should never be used without properly grounded electrical connections. Do not use in wet or damp locations or expose to rain.WARNINGAIR TOOLS AND ACCESSORIES WARNING: Do not exceed the pressure rating of any air tools, spray guns, air accessories, or inflatables. Excess pressure can cause them to explode, resulting in serious injury. Follow the manufacturers recommended pressure set-tings for all air tools and air accessories.WARNINGDo not direct compressed air stream at people or pets. The powerful compressed air stream can damageexposed skin and easily propel loose dirt and other small objects. Always wear eye protection that meetsANSI Z28.1 specifications.WARNINGKeep hands and fingers away from exposed metal parts on a running air compressor. Air compressors gener-ate significant heat during normal operation, which can cause serious burns. The compressor will remain hot for some time after operation and should not be touched or moved until cool.10safetyGeneral Safety InformationDo not operate unit if damaged during shipping, handling or use. Damage may result in bursting and cause injury or property damage.Since the air compressor and other components (filters, lubricators, hoses, etc.) used, make up a high pressure pumping system, the follow-ing safety precautions must be observed at all times:1. Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment.2. Follow all local electrical and safety codes3. Only persons well acquainted with these rules of safe operation should be allowed to use the compressor.4. Keep visitors away and NEVER allow children in the work area.5. Wear safety glasses and use hearing protection when operating the pump or unit.6. Do not stand on or use the pump or unit as a handhold.7. Before each use, inspect compressed air system and electrical components for signs of damage, deterioration, weakness or leakage. Repair or replace defective items before using.8. Check all fasteners at frequent intervals for proper tightness.WARNINGCompressor parts may be hot even if the unit is stopped.9. Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/or burns.10. If the equipment should start to abnormally vibrate, STOP the engine/ motor and check immediately for the cause. Vibration is generally a warning of trouble.11. To reduce fire hazard, keep engine/motor exterior free of oil, solvent, or excessive grease. Never remove or attempt to adjust safety valve. Keep safety valve free from paint and other accumulations.12. Never attempt to repair or modify a tank Welding, drilling or any other WARNINGMotors, electrical equipment and controls can cause electrical arcs that will ignite a flammable gas or vapor. Never operate or repair in or near a flammable gas or vapor. Never store flammable liquids or gases in the vicinity of the compressor. 11safetyWARNINGDo not spray flammable materials in vicinity of open flame or near ignition sources including the compressorunit. modification will weaken the tank resulting in damage from rupture or explosion. Always replace worn or damaged tanks. Drain liquid from tank daily.13. Tanks rust from moisture build-up, which weakens the tank. Make sure to drain tank daily and inspect periodically for unsafe conditions such as rust formation and corrosion.14. Fast moving air will stir up dust and debris which may be harmful. Release air slowly when draining moisture or depressurizing the compressor system.Spraying Precautions15. Do not smoke when spraying paint, insecticides, or other flammable substances.16. Use a face mask/respirator when spraying and spray in a well ventilated area to prevent health and fire hazards.17. Do not direct paint or other sprayed material at the compressor. Locate compressor as far away from the spraying area as possible to minimize overspray accumulation on the compressor.18. When spraying or cleaning with solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer.Hose Precautions19. Inspect hose before use. Do not exceed working pressure marked on hose. Do not twist, bend knot, or abrade hose. Do not wrap hose around body.20. Keep away from hot surfaces and chemicals.WARNINGArcing Parts. Keep the compressor/motor at least 6m away from explosive vapour.12installation & groundingInstallation and LocationThe compressor must be used on a stable level surface. The air compres-sor must be used in a clean and well-ventilated area. The compressor requires an unobstructed airflow and must be located a minimum of 18 inches from any walls or other obstructions.Grounding InstructionsThis product should be grounded. In the event of an electrical short cir-cuit, grounding reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is properly installed and grounded in accor-dance with all local codes and ordinances.This product is for use on a nominal 120-volt circuit and has a three-prong grounding plug that looks like the plug illustrated in Figure 2. Make sure that the product is connected to an outlet having the sameconfiguration as the plug. No adapter could be used with this product.The use of a GFCI outlet is strongly recommended. The third prong isto be used ground the tool and provide protection against electricalshock. Never remove the third prong.Check with a qualified electrician or serviceman if the grounding instruc-tions are not completely understood, or if In doubt as to whether the product is properly grounded. Do not modify the plug provided; if it will not fit the outlet, have the proper outlet installed by a qualified electrician.DANGERELECTRIC SHOCK: Improper installation of the grounding plug can result in a risk of electric shock. If repair or replacement of the cord is necessary, do not connect the grounding wire to either flat blade terminal. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.Figure 2Grounding Pin Grounded Outlet13installation & groundingExtension CordsWe do not recommend the use on an extension cord with this product as this may result in the loss of power and overheating of the motor. An additional air hose should be used instead of an extension cord. However, if the use of an extension cord is unavoidable, use only UL listed wire extension cords that have three-pronged grounding type plugs and three prong receptacles that accept the tool’s plug. Improper use of extension cords may cause inefficient operation of you tool, which can result an overheating. Be sure your extension cord is rated to allow sufficient flow to motor. Refer to the guide for minimum gauge required for extension cords.Use of an extension cord heavy enough to carry the current the tool will draw is very important. Especially when the power source is of great distance. An extension cord that is insufficient will cause a drop in line voltage, resulting in power loss and causing the motor to overheat.Guard against electrical shock. Avoid body contact with grounded ser-vices such as pipes, radiators, ovens, stoves, and refrigerator enclosures. If not properly grounded, this power tool can incur the potential hazard of light trickle shock, particularly when used in damp locations. If an electri-cal shock occurs, there is the potential of a secondary hazard such as your hands contacting an operating air tool.Extension Cord Length Wire Size (A.W.C.)Up to 25 Feet 1426 to 50 Feet 1251 to 100 Feet 1014assembly instructionsWARNINGThe compressor is shipped without oil in the crankcase. Add oil as indicated below.AssemblyRead all safety instructions before using air compressor. 1. After opening the carton, please remove all parts and check against photograph on carton. If any parts are missing, please call at 1-866-850-6662.2. Place air compressor on a flat, level surface.3. Pour supplied oil into crankcase until the oil level reaches the red dot in the oil level sight glass. Be careful not to overfill.4. Install oil fill plug, supplied for compressor operation, before starting compressor.5. Close tank drain valve on the bottom of the air tank by turning the valve clockwise until fully closed.6. Attach the air coupler to the compressor regulator valve. Use Teflon thread-sealing tape on the threads to make sure you have an airtight connection. Do not over tighten fittings.7. Attach the supplied air filter to the air intake port on the pump head.8. Attach air hose and any desired air accessories (which are not included). Use Teflon thread-sealing tape on the threads to make sure you have an airtight connection. Do not over tighten fittings.Refill Oil ImmediatelyCheck Oil Level DailyOil Level OKNOTICEDo not operate the compressor without lubricant or with low lubricant level. We are not responsible for damage caused to the compressor due to operation without proper lubrication.product features15assembly instructionsProduct Features1. Automatic ON/OFF Pressure Switch The compressor is equipped with an automatic on/off pressure switch. The compressor will only run when the switch is in the “I”(ON) position. Once the tank has reached the desired preset pressure (see Operation Instructions), the pump motor will automatically shut off. While the switch is in the “I”(ON) position, the pump motor will automatically turn back on once the pressure in the tank drops below the minimum preset pressure. Do not leave the compressor unattended while the power switch is in the “I”(ON) position.2. Regulator The regulator allows you to select the amount of air pressure that is output through the air hose into tools and accessories. Please refer to the air delivery requirements of your tools for the proper pressure settings.3. Tank Pressure Gauge The tank pressure gauge provides a reading of the air pressure inside of the compressor tank.4. Safety Valve This compressor is equipped with a safely valve switch that will engage when the pressure in the tank exceeds the maximum rated pressure. DO NOT attempt to modify or remove safely valve.5. Tank Drain Fitting Water is produced whenever air is compressed. It is critical to drain water from the air tank on this compressor frequently. If unit is used only occasionally, tank should be drained after each use and prior to the next use. To drain the tank, slowly open the tank drain fitting by turning clockwise. Once all water has drained out, close the fitting securely.NOTE: tank will not pressurize while fitting is open.6. Thermal Shutdown Switch The electric motor is equipped with an automatic thermal overload protector. If the unit is overheating, the motor will automatically shut down. Turn the unit off and wait 5-10 minutes before turning the unit back to the “I”(ON) position. If the unit shuts down again, please contact the manufacturer for assistance.product features16operationOperating InstructionsInitial Start Up1. Disconnect tools and/or accessories from the air hose.2. Open the tank drain valve to allow air to escape preventing air pressure buildup in the air tank.3. Plug power supply cord into proper power source receptacle. (See Grounding Instructions)4. Run the compressor for a minimum or twenty minutes in this no-load position to lubricate the bearings and piston.5. Turn off compressor, drain liquid from tanks and close drain valve.6. The compressor is now ready for use.Start Up1. Slowly open tank drain by turning clockwise. Allow any water in tank to drain out. Close fitting securely.2. Before connecting the compressor to the grounded outlet, check for broken components and accessories, and check for damage to the hose.3. Make sure the power switch is turned “O”(OFF) position.4. Plug the unit into a grounded outlet.5. Attach desired tool to the end of the air hose.6. Turn the switch on the “I”(ON) position.7. Adjust regulator knob to desired pressure level once the pump has shut off and the compressor has stopped running.Storage1. Disconnect unit from grounded outlet.2. Disconnect tools and/or accessories from the air hose.3. Locate drain valve on bottom side of tank.4. Open drain valve to release remaining pressurized air and moisture from the air tank. Moisture buildup in the tank is normal with air compressors, so a small amount of water may come out while draining the tank. Draining the tank is vital for longevity and safety of your air compressor.5. Close valve and store the compressor in a cool, dry place.Shut Down1. Do not turn off the air compressor by unplugging it from the power receptacle as damage may result.2. Turn the ON/OFF lever to the OFF position.3. Unplug power cord from outlet.4. Rotate the pressure regulator knob counterclockwise until it is fully closed. Check regulated pressure gauge to ensure that it reads 0 PSI.5. Remove air hose and other connected accessories.operation & maintenance 17operation operation & maintenance 6. Slowly open air tank drain valve to release remaining pressurized air, and tilt unit to fully drain accumulated liquid from air tanks. Moisture build-up in the tank is normal with air compressor, so a small amount of water may come out while draining the tank. Draining the tank is vital for the longevity and safely of your air compressor.7. Close drain valve.8. Allow compressor to cool down.9. Clean and store compressor.MaintenanceWhen performing any maintenance or service· The air compressor must be turned off.· Disconnect compressor from the power source.· Drain tanks.· Allow compressor to cool down.Daily· Check oil level.· Drain accumulated liquid from tanks.· Check for oil leaks.· Check for unusual noise and/or vibrations· Check that all fasteners are secure.Weekly· Check safety relief valve.· Inspect and clean air filter.· Clean breather holes on oil check dipstick.Monthly· Check for air leaks. · Apply a solution of soapy water around joints. · Look for air bubbles around joints when compressor reaches the pressure cut-out limit and pump turns off.Six Months or 250 Operating Hours· Change compressor oil. · Use only SAE 20 or SAE 30 weight non-detergent oil.· Replace oil more frequently when used in dusty operating environments.Oil Change1. Place oil drain pan below oil drain plug.2. Remove dipstick to allow air to enter crankcase.3. Remove oil drain plug.4. Allow oil to drain completely.5. Clean and replace oil drain plug.6. Refill crankcase with SAE 20 or SAE 30 weight non-detergent oil to red dot on oil level sight glass. Be careful not to overfill.18partsAC205 Parts Diagramparts19partspartsAC205 Parts ListNo. Description Qty1 Bolt 42 Washer 43 Air Filter includes element 14 Cylinder Head 15 Elbow 16 Shroud 17 Washer 48 Washer 49 Bolt 410 Head Gasket 111 Valve plate 212 Valve 213 Metal gasket 114 Valve plate gasket 115 Nut 216 Bolt 217 Washer 218 Cylinder 119 Cylinder Gasket 120 Piston Ring Set 121 Compression Ring 222 Oil Ring 123 Piston 124 Wrist pin 125 Wrist pin retainer 226 Connecting Rod 127 Bolt 128 Washer 129 Camshaft lobe 130 Breather tube 131 "O'' Ring 132 Crankcase Cover gasket 133 Crankcase Cover 134 "O'' Ring 135 Sight glass 136 "O'' Ring 137 Bolt 138 Bolt 4No. Description Qty39 Washer 440 Crankcase 141 Over-load 142 Nut 143 Capacitor 144 Motor 145 Rear cover 146 Fan 147 Clip 148 Outlet Tube Assy 149 Rubber strip 150 Control panel 151 Bolt 852 Pressure Regulator 153 Safety Valve 154 Pressure Gauge 255 Coupler 256 Plug 357 Bolt 258 Elbow 259 Pressure Switch 160 Hoop 261 Pipe 162 Unloader tube 163 Handle 164 Tank 165 Drain valve 166 Check valve 167 Foot 468 Bolt 469 Bolt 470 Base 171 Connecting pad 472 Washer 473 Washer 474 Nut 475 Power Cord 176 Motor cord 0.85mIf you need assistance with the assembly or operation of this Compressor please call 1-866-850-6662