Owner's Manual

Permanently LubricatedSingle StageVertical Portable

AIR COMPRESSOR

Model No.919.165190

• Safety Guidelines

• Assembly

• Operation

• Maintenance

• Service and Adjustments

• Troubleshooting

• Repair Parts

• Espa_ol

CAUTION; Read the Safety Guidelines

and All Instructions Carefully BeforeOperating.

Sears, Roebuck and Co., Hoffman Estates, IL 60170 U,S.A.visit our Craftsman website: www.sears.com/craftsmen

D2458a Rov. O 10111/01

WARRANTY ........................................... 2

SPECIFICATION CHART .................................... 3

SAFETY GUIDELINES .................................... 3-8

GLOSSARY .............................................. 9

ACCESSORIES ......................................... 9

DUTY CYCLE ............................................ 9

ASSEMBLY ............................................. 10

INSTALLATION ........................................ 11-12

OPERATION .......................................... 13-15

MAINTENANCE ....................................... 16-17

SERVICE AND ADJUSTMENTS ........................... 18 19

STORAGE .............................................. 20

TROUBLESHOOTING GUIDE ............................ 21-23

REPAIR PARTS ....................................... 24-27

ESPAI_IOL ............................................ 28-49

HOW TO ORDER REPAIR PARTS ..................... back cover

FULL ONE YEAR WARRANTY AIR COMPRESSOR

If this air compressor fails due to a defect in material or workmanship withinone year from the date of purchase, RETURN IT TO THE NEAREST SEARSREPAIR CENTER THROUGHOUT THE UNITED STATES AND SEARS WILL.REPAIR IT, FREE OF CHARGE. If purchased from Orchard Supply Hardware,return to the nearest Orchard Store and Orchard will repair it, free of charge.

If this air compressor is used for commercial or rental purposes, the warrantywilt apply for ninety days from the date of purchase.

This warranty gives you specific legal rights and you may have other rightswhich vary from state to state.

Sears, Robebuck and Co., Dept. 817WA, Hoffman Estates, II 60179

D24588 2-ENG

Model No. 919-165190

Max. Developed HP 5.5Bore 2.38"Stroke 1.35"

Voltage-Single Phase 120Minimum Branch Circuit Requirement 15 ampsFuse Type Time DelayAir Tank Capacity 25 gallonsApproximate Cut-in Pressure 110Approximate Cut-out Pressure 135SCFM @ 40 psig 8.4SCFM @ 90 psig 6.2

Refer to Glossary for abbreviations,

This manual contains information that is important for you to know end understand. This informationrelates to protecting YOUR SAFETY end PREVENTING EQUIPMENT PROBLEM8. To help you rec-

ognize th{s information, we use the symbols below. Please road the manual end pay attention to these_ctions.

_lndicates an imminent-ly hazardous situation

i which, if not avoided, _ result inorse'o sin'u ,

F_q_lndicates a potentiallyhazardous situation

which, if not avoided, coul._ddresult indeath or serieu_ injqrY,

_}ndicates a potentially"_'m"" hazardo us situation

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

_Used without thesafety alert symbol

indicates a potentially hazardous situation which, if not avoided, mayresult in Drenertv damaog.

Some dust created by power sanding, sawing, grinding, drilling, and other con-sfructlon activities contains chemicals known (to the State of California) to cause

cancer, birth defects or other reproductive 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 lumber

Your risk: from these exposures varies, depending on how otten you do this type of work. re reduce

your exposure to these chemicals: work in a well ventilated area, and work with approved safetyequipment, always wear MSHA/NIOSH approved, prooerly fitting face mask or respirator when usingsuch too{s.

When uaing air tools, basic safety precautions should atways be followed to reduce the risk of of per-sonal injury.

3-ENG D24588

IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT INSERIOUS INJURY AND PROPERTY DAMAGE. RF_AD AND UNDERSTAND ALL WARN-

INGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT.

SAVE THESE INSTRUCTIONS

WARNING: RISK OF EXPLOSION OR FIRE

WHAT CAN HAPPEN

IT IS NORMAL FOR ELECTRICAL CONTACTSWITHIN THE MOTOR AND PRESSURE SWITCHTO SPARK.

IFELECTRICALSPARKSFRoMCOMPreS-SORCOME INTO CONTACT WITH FLAMMA-BLE VAPORS, THEY MAY IGNITE, CAUSINGFIRE OR EXPLOSION.

RESTRICTING ANY OF THE COMPRESSORVENTILATION OPENINGS WILL CAUSE SERI-OUS OVERHEATING AND COULD CAUSEFIRE.

UNATTENDED OPERATION OF THIS PROD-UCT COULD RESULT IN PERSONAL INJURYOR PROPERTY DAMAGE. TO REDUCE THERISK OF FIRE, DO NOT ALLOW THE COM-PRESSOR TO OPERATE UNA'FrENDED.

HOW TO PREVENT IT

ALWAYS OPERATE THE COMPRES_OR IN AWELL VENTILATED AREA FREE OF COM-BUSTIBLE MATERIALS, GASOLINE OR SOL-VENT VAPORS.

IF SPRAYING FLAMMABLE MATERIALS,LOCATE COMPRESSOR AT LEAST 20 FEETAWAY FROM SPRAY AREA. AN ADDITIONALLENGTH OF HOSE MAY BE REQUIRED,

STORE FLAMMABLE MATERIALS IN ASECURE LOCATION AWAY FROM COMPRES-SOR.

NEVER PLACE OBJECTS AGAINST OR ONTOP OF COMPRESSOR. OPERATE COM-PRESSOR tN AN OPEN AREA AT LEAST 12INCHES AWAY FROM ANY WALL OROBSTRUCTION THAT WOULD RESTRICT THEFLOW OF FRESH AIR TO THE VENTILAT]ONOPENINGS.

OPERATE COMPRESSOR IN A CLEAN, DRY,WELL VENTILATED AREA DO NOT OPERATEUNIT INDOORS OR IN ANY CONFINED AREA,

ALWAYS REMAIN IN ATTENDANCE WITH THEPRODUCT WHEN IT IS OPERATING.

ALWAYS DISCONNECT ELECTRICAL POWERBY MOVING PRESSURE SWITCH LEVER TOTHE OFF POSITION AND DRAIN "rANK DAILYOR AFTER EACH USE.

D24588 4 ENG

WARNING: RISK OF BURSTING I'll

AIR TANK: THE FOLLOWING CONDITIONS COULD LEAD TO A WEAKENING OF THETANK, AND RESULT IN A VIOLENT TANK EXPLOSION AND COULD CAUSE PROP-ERTY DAMAGE OR SERIOUS INJURY,

WHAT CAN HAPPEN/

1. FAILURE TO PROPERLY DRAIN CON-DENSED WATER FROM THE TANK,CAUSING RUST AND THINNING OF

THE STEEL TANK.

2, MODIFICATIONS OR ATTEMPTED

REPAIRS TO THE TANK.

3, UNAUTHORIZED MODIFICATIONS TOTHE UNLOADER VALVE, SAFETY

VALVE, OR ANY OTHER COMPONENTSWHICH CONTROL TANK PRESSURE.

4. EXCESSIVE VIBRATION CAN WEAKENTHE AIR TANK AND CAUSE RUPTUREOR EXPLOSION.

ATTACHMENTS & ACCESSORIES:

EXCEEDING THE PRESSURE RATING OF AIR

TOOLS, SPRAY GUNS. AIR OPERATEDACCESSORIES, TIRES AND OTHER INFLATA-BLES CAN CAUSE THEM TO EXPLODE OR

FLY APART, AND COULD RESULT IN SERIOUSINJURY.

HOW TO PREVENT IT

DRAIN TANK DAILY OR AFTER EACH USE. iF

TANK DEVELOPS A LEAK, REPLACE IT IMMEDI-ATELY WiTH A NEW TANK OR REPLACE THE

ENTIRE COMPRESSOR

NEVER DRILL INTO, WELD, OR MAKE ANYMODIFICATIONS TO THE TANK OR ITSATrACH MENTS.

THE TANK IS DESIGNED TO WITHSTAND SPE-CIFIC OPERATING PRESSURES. NEVER MAKEADJUSTMENTS OR PARTS SUBSTITUTIONSTO ALTER THE FACTORY SET OPERATING

PRESSURES.

FOR 'ESSENTIAL CONTROL OF AIR

PRESSURE,YOU MUST INSTALL A PRESSUREREGULATOR AND PRESSURE GAUGE TO

THE AIR OUTLET (IF NOT EQUIPPED) OFYOUR COMPRESSOR. FOLLOW THE EQUIP-MENT MANUFACTURERS RECOMMENDATION

AND NEVER EXCEEDTHE MAXIMUM ALLOW-ABLE PRESSURE RATING OF A_ACHMENTS.NEVER USE COMPRESSOR TO INFLATESMALL LOW-PRESSURE OBJECTS SUCH AS

CHILDREN'S TOYS, FOOTBALLS, BASKET-BALLS, ETC,

WARNING: RISK FROM FLYING OBJECTS

WHAT CA N HAP, PEN

THE COMPRESSED AIR STREAM CANCAUSE SOFT TISSUE DAMAGE TO EXPOSED

SKIN AND CAN PROPEL DIRT, CHIPS, LOOSEPARTICLES AND SMALL OBJECTS AT HIGH

SPEED, RESULTING IN PROPERTY DAMAGEOR PERSONAL INJURY.

HOw To PREVENT IT

ALWAYS WEAR ANSI Z87.1 APPROVED SAFE-TY GLASSES WITH SIDE SHIELDS WHEN

USING THE COMPRESSOR.

NEVER POINT ANY NOZZLE OR SPRAYER

TOWARD ANY PART OF THE BODY OR ATOTHER PEOPLE OR ANIMALS.

ALWAYS TURN THE COMPRESSOR OFF ANDBLEED PRESSURE FROM THE AIR HOSE AND

TANK BEFORE ATTEMPTING MAINTENANCE,All-ACHING TOOLS OR ACCESSORIES.

5-ENG 024588

I EY J rJ l

WARNING: RISK OF ELECTRICAL SHOCK

WHAT CAN HAPPEN

YOUR AIR COMPRESSOR IS POWERED BYELECTRICITY. LIKE ANY OTHER ELECTRI-CALLY POWERED DEVICE. IF IT IS NOT USEDPROPERLY IT MAY CAUSE ELECTRICSHOCK,

REPAIRS ATTEMPTED BY UNQUALIFIED PER-

SONNEL CAN RESULT IN SERIOUS INJURYOR DEATH BY ELECTROCUTION.

ELECTRICAL GROUNDING: FAILURE TOPROVIDE ADEQUATE GROUNDING TO THISPRODUCT COULD RESULT IN SERIOUSINJURY OR DEATH FROM ELECTROCUTION,SEE GROUNDING iNSTRUCTIONS

HOW TO 'PREVENT IT

NEVER OPERATE THE COMPRESSOR OUT-DOORS WHEN IT IS RAINING OR 1N WET CON-DITIONS.

NEVER OPERATE COMPRESSOR WITH PRO-TECTIVE COVERS REMOVED OR DAMAGED.

ANY ELECTRICAL WIRING OR REPAIRSREQUIRED ON THIS PRODUCT SHOULD BE

PERFORMED BY AUTHORIZED SERVICECENTER PERSONNEL IN ACCORDANCE WITHNATIONAL AND LOCAL ELECTRICAL CODES.

MAKE CERTAIN THAT THE ELECTRICAL CIR-CUIT TO WHICH THE COMPRESSOR IS CON-NECTED PROVIDES PROPER ELECTRICALGROUNDING, CORRECT VOLTAGE AND ADE-QUATE FUSE PROTECTION.

WARNING: RISK TO BREATHING

WH_T CAN HAPPEN HOW TO PREVENT IT

THE COMPRESSED AIR DIRECTLY FROMYOUR COMPRESSOR IS NOT SAFE FORBREATHING. THE AIR STREAM MAY CON-

TAIN CARBON MONOXIDE, TOXIC VAPORS,OR SOLID PARTICLES FROM THE TANK.

BREATHING THESE CONTAMINANTS CANCAUSE SERIOUS INJURY OR DEATH.

SPRAYED MATERIALS SUCH AS PAINT, PAINTSOLVENTS, PAINT REMOVER, INSECTICIDES,WEED KILLERS, MAY CONTAIN HARMFULVAPORS AND POISONS.

AIR OBTAINED DIRECTLY FROM THE COM-PRESSOR SHOULD NEVER BE USED TOSUPPLY AIR FOR HUMAN CONSUMPTION. iNORDER TO USE AIR PRODUCED BY THIS

COMPRESSOR FOR BREATHING, SUITABLEFILTERS AND IN-LINE SAFETY EQUIPMENT

MUST BE PROPERLY INSTALLED. IN-LINEFILTERS AND SAFETY EQUIPMENT USED INCONJUNCTION WITH THE COMPRESSORMUST BE CAPABLE OF TREATING AIR TOALL APPLICABLE LOCAL AND FEDERAL

CODES PRIOR TO HUMAN CONSUMPTION.

WORK IN AN AREA WITH GOOD CROSS-VENTILATION. READ AND FOLLOW THESAFETY INSTRUCTIONS PROVIDED ON THELABEL OR SAFETY DATA SHEETS FOR THEMATERIAL YOU ARE SPRAYING. USE ANIOSH/MSHA APPROVED RESPIRATORDESIGNED FOR USE WITH YOUR SPECIFIC

APPLICATION,

D24586 6-ENG

WARNING: RISK OF BURNS

WHAT CAN HAPPEN HOW TO PREVENT IT

TOUCHING EXPOSED METAL SUCH AS THECOMPRESSOR HEAD OR OUTLET TUBES,CAN RESULT IN SERIOUS BURNS.

NEVER TOUCH ANY EXPOSED METALPARTS ON COMPRESSOR DURING OR IMME-DIATELY AFTER OPERATION. COMPRESSORWILL REMAIN HOT FOR SEVERAL MINUTESAFTER OPERATION.DO NOT REACH AROUND PROTECTIVESHROUDS OR A'I-FEMPT MAINTENANCEUNTIL UNIT HAS BEEN ALLOWED TO COOL.

WARNING: RISK FROM MOVING PARTS _

WHAT CAN HAPPEN How TO P.I_,EyENT IT

MOVING PARTS SUCH AS THE PULLEY, FLY- NEVER OPERATE THE COMPRESSOR WITHWHEEL AND BELT CAN CAUSE SERIOUS GUARDS OR COVERS WHICH ARE DAMAGEDINJURY iF THE"YCOME tNTO CONTACT WITH OR REMOVED.YOU OR YOUR CLOTHING.

A'I-rEMPTING TO OPERATE COMPRESSOR -ANY REPAIRS REQUtRED ON THIS PRODUCTWITH DAMAGED OR MISSING PARTS OR SHOULD BE PERFORMED BY AUTHORIZEDATTEMPTING TO REPAIR COMPRESSOR SERVICE CENTER PERSONNEL.WITH PROTECTIVE SHROUDS REMOVED CANEXPOSE YOU TO MOVING PARTS AND CANRESULT IN SERIOUS INJURY.

WARNING: RISK OF FALLING

WHAT CAN HAPPEN

A PORTABLE COMPRESSOR CAN FALLFROM A TABLE, WORKBENCH OR ROOFCAUSING DAMAGE TO THE COMPRESSORAND COULD RESULT IN SERIOUS INJURY

OR DEATH TO THE OPERATOR.

HOW TO PREVENT IT

ALWAYS OPERATE COMPRESSOR IN A STA-BLE SECURE POSITION TO PREVENT ACCI-DENTAL MOVEMENT OF THE UNIT. NEVEROPERATE COMPRESSOR ON A ROOF OROTHER ELEVATED POSITION. USE ADDI-TIONAL AIR HOSE TO REACH HIGH LOCA-TIONS.

7-ENG D24588

WARNING: RISK OF PROPERTY DAMAGE WHEN TRANS-

pORTING COMPRESSOR

(Fire, Inhalation, Damage to Vehicle Surfaces)

WHAT CAN HAPPEN

OIL CAN LEAK OR SPILL AND COULDRESULT IN FiRE OR BREATHING HAZARD,SERIOUS INJURY OR DEATH CAN RESULT.OIL LEAKS WILL DAMAGE CARPET, PAINT OROTHER SURFACES IN VEHICLES OR TRAIL-

ERS

i

HOW TO PREVENT IT

ALWAYS PLACE COMPRESSOR ON A PRO-TECTIVE MAT WHEN TRANSPORTING TOPROTECT AGAINST DAMAGE TO VEHICLEFROM LEAKS. REMOVE COMPRESSOR FROMVEHICLE IMMEDIATELY UPON ARRIVAL ATYOUR DESTINATION.

WARNING: RISK OF UNSAFE OPERATION

WH_&T CAN HAPPEN

UNSAFE OPERATION OF YOUR AIR COM-PRESSOR cOULD LEAD TO SERIOUS INJURYOR DEATH TO YOU OR OTHERS,

HOW T.Q, P,,_Ey_ENT IT

REVIEW AND UNDERSTAND ALL INSTRUC-TIONS AND WARNINGS IN THIS MANUAL.

BECOME FAMILIAR WITH THE OPERATIONAND CONTROLS OF THE AIR COMPRESSOR.KEEP OPERATING AREA CLEAR OF ALL PER-SONS, PETS, AND OBSTACLES.KEEP CHILDREN AWAY FROM THE AIR COM-PRESSOR AT ALL TIMES.DO NOT OPERATE THE PRODUCT WHENFATIQUED OR UNDER THE INFLUENCE OFALCOHOL OR DRUGS. STAY ALERT AT ALLTIMES.NEVER DEFEAT THE SAFETY FEATURES OFTHIS PRODUCT.EQUIP AREA OF OPERATION WITH A FIREEXTINGUISHER.DO NOT OPERATE MACHINE WITH MISSINQ,BROKEN, OR UNAUTHORIZED PARTS.

D24588 8-ENG

Become familiar with these termsbefore operating the unit.

CFM: Cubic feet per minute.SCFM: Standard cubic feet perminute; a unit of measure of air deliv-

ery.PSIG; Pounds per square inchgauge; 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 restartautomatically. The low pressure atwhich the motor automaticallyrestarts is called "cut-in" pressure.Cut-Out Pressure: When an air

compressor is turned on and beginsto run, air pressure in the air tankbegins to build. It builds to a certainhigh pressure before the motor auto-matically shuts off, protecting your airtank from pressure higher than itscapacity. The high pressure at whichthe motor shuts off is called "cut-out"

pressure.Branch Circuit: Circuit carrying elec-tricity from electrical panel to outlet.

This unit is capable of powering the following Accessories. The accessories are

available through the current Power and Hand Tool Catalog or full-line Searsstores.

Accessories

• In Line Filter

• Tire Air Chuck

• Quick Connector Sets (varioussizes)

• Air Pressure Regulators

• Oil Fog Lubricators• Air Hose:l/4", 3/8" or 1/2" I.D. in

various lengths

Refer to the selection chart locatedon the unit to select the tools this unit

is capable of powering.

Air compressors should be operatedon not more than a 50% duty cycle.This means an air compressor thatpumps air more than 50% of onehour is considered misuse, because

the air compressor isundersized forthe required air demand. Maximumcompressor pumping time per hour is30 minutes.

9-ENG D24588

Contents of Carton

1 - Air Compressor

2- Wheels

2 - Shoulder Bolts, 3/8-16

2 - Hex Nuts, 3/8-16

2 - Rubber Bumpers

2 - Screws, 1/4-20 x .75"

Tools Required for Assembly

1 - 9/16" socket or open end wrench

1 - 1/2" socket or open end wrench

Unpacking

1. Remove all packaging leavingthe air compressor on the pallet.

2. Remove and discard the (4)screws holding the air compres-sor to the pallet.

Assemble Wheels

It will be necessaryto brace or support

one side of the air compressorwhen installing the wheels becausethe air compressor will have a ten-dency to tip.

1. Attach wheels with shoulderbolts and nuts as shown.

fl _ Rubber

et

crew

ShoulderBo|t

It may be neces-saw to brace or

support one side of the air com-

pressor when removing the palletbecause the air compressor willhave a tendency to tip.

3. Carefully remove the air com-

pressor from the pallet.

2. Tighten securely. NOTE: The aircompressor will sit level if the

wheels are properly installed.

The wheels andhandle do not pro-

vide adequate clearance, stabilityor support for pulling the unit upand down stairs or steps. The unitmust be lifted, or pushed up aramp.Assemble Rubber Feet

!. Attach rubber feet with the

screws provided as shown inprevious figure,

2. Tighten securely.

D24588 10- ENG

HOW TO SET UP YOURUNIT

Location of the Air Compressor

Locate the air compressor in a clean,dry and well ventilated area. The aircompressor should be located atleast 12" away from the wall or otherobstructions that will interfere withthe flow of air. The air compressorpump and shroud are designed toallow for proper cooling. The ventila-tion openings on the compressor arenecessary to maintain proper operat-ing temperature. Do not place rags orother containers on or near these

openings,The air filter must be keptclear of obstructions which could

reduce air flow to the air compressor.

GROUNDING INSTRUCTIONS

RISK OF ELECTRI-CAL SHOCK. In

the event of a short circuit, ground-ing reduces the risk of shook byproviding an escape wire for theelectric current. This air compres-sor must be properly grounded.

The portable air compressor isequipped with a cord having agrounding wire with an appropriategrounding plug (see following illustra-tions). The plug must be used withan outlet that has been installed andgrounded in accordance with all localcodes and ordinances.

. The cord set and plug with thisunit contains a grounding pin.This plug MUST be used with agrounded outlet.

IMPORTANT: The outlet being usedmust be installed and grounded inaccordance with all local codes andordinances.

. Make sure the outlet being usedhas the same configuration asthe grounded plug. DO NOTUSE AN ADAPTER. See illustra-tion.

3. Inspect the plug and cord beforeeach use. Do not use if there are

_ Grounded/Outlets

Grou d_in9 Pin

signs of damage.

4. If these grounding instructionsare not completely understood,or if in doubt as to whether thecompressor is properly ground-ed, have the installation checkedby a qualified electrician.

_ IMPROPERGROUNDING CANRESULT IN ELECTRICAL SHOCK.

Do not modify the plug provided. Ifit does not fit the available outlet, acorrect outlet should be installedby a qualified electrician.

Repairs to the cord set or plugMUST be made by a qualified elec-trician,

11-ENG _24588

Extension Cords

Using extension cords is not recom-mended. The use of extension cords

will cause voltage to drop resulting in

power loss to the motor and over-heating.

Instead of using extension cordsattach extra air hoses to each other

starting at the air outlet.

If an extension cord must be used,be sure it is:

• a 3-wire extension cord that has

a 3-blade grounding plug, and a3-slot receptacle that will acceptthe plug on the product

- in good condition

• no longer than 50 feet

• 12 gauge (AWG) or larger. (Wiresize increases as gauge numberdecreases. 10 AWG and 8 AWG

may also be used. DO NOT USE14 OR 16 AWG.)

Voltage and Circuit Protection

Refer to the specification table for thevoltage and minimum branch circuitrequirements.

Certain air compressors can be oper-ated on a 15 amp circuit if the follow-

[ng conditions are met.

1. Voltage supply through branchcircuit is 15 amps.

2. Circuit is not used to supply any

other electrical needs (lights,appliances, etc.).

3. Extension cords comply withspecifications.

4. Circuit is equipped with a 15amp circuit breaker or 15 amptime delay fuse. NOTE: If com-

pressor is connected to a circuitprotected by fuses, use only timedelay fuses, Time delay fusesshould be marked "D" in Canadaand "T" in the US.

If any of the above conditions cannotbe met, or if operation of the com-pressor repeatedly causes interrup-

tion of the power, it may be neces-sary to operate it from a 20 amp cir-

cuit. It is not necessary to change thecord set.

D24588 12 ENG

Know Your Air Compressor

READ THIS OWNER'S MANUAL AND SAFETY RULES BEFORE OPERATING

YOUR UNIT. Compare the illustrations with your unit to familiarize yourself withthe location of various controls and adjustments. Save this manual for futurereference.

Switch

Safety Valve

Description of OperationBecome familiar with these controls

before operating the unit.On/Auto/Off Switch: Turn this switchON to provide automatic power tothe pressure switch and OFF toremove power at the end of eachuse.

Pressure Switch: The pressureswitch automatically starts the motorwhen the air tank pressure dropsbelow the factory set "cut-in" pres-sure, it stops the motor when the airtank pressure reaches the factory set"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 its fac-tory set pressure (slightly higher thanthe pressure switch "cut-out" setting),

Outlet Pressure Gauge: The outletpressure gauge indicates the air pres-sure available at the outlet side of theregulator. This pressure is controlledby the regulator and is always lessthan or equal to the tank pressure.

Tank Pressure Gauge: The tankpressure gauge indicates the reserveair pressure in the tank.

Regulator: Controls the air pressureshown on the outlet pressure gaugePull the knob out and turn clockwiseto increase pressure and counter-clockwise to decrease pressure.When the desired pressure is reachedpush knob in to lock in place.Drain Valve: The drain valve is locat-ed at the base of the air tank and isused to drain condensation at theend of each use.

Cooling System (not shown): Thiscompressor contains an advanceddesign cooling system. At the heartof this cooling system is an engi-neered fan. It is perfectly normal forthis fan to blow air through the ventholes in large amounts You knowthat the cooling system is workingwhen air is being expelled.

33-ENG D24588

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.

Check Valve: When the air compres_sor is operating, the check valve is"open", allowing compressed air toenter the air tank. When the air com-pressor reaches "cut-out" pressure,the check valve "closes", allowing airpressure to remain inside the air tank.

If the overload protector shuts themotor off frequently, check for a pos-sible voltage problem, Low voltagecan also be suspected when:

1. The motor does not get up to full

power or speed.

2. Fuses blow out when startingthe motor; lights dim and remaindim when motor is started and is

running.

How to Use Your Unit

How to Stop:

1. Set the On/Auto/Off lever to

"OFF".

Pressure Release Valve: The pres-sure release valve located on the side

of the pressure switch, is designed toautomatically release compressed airfrom the compressor head and theoutlet tube when the air compressorreaches "cut-out" pressure or is shutoff. The pressure release valve allowsthe motor to restart freely. When themotor stops running, air will be heardescaping from this valve for a fewseconds. No air should be heard

leaking when the motor is running orafter the unit reaches "cut-out" pres-sure.

ReleaseValve

Motor Overload Protector: Themotor has an automatic reset thermaloverload protector. If the motor over-heats for any reason, the overloadprotector will shut off the motor. Themotor must be allowed to cool down

before restarting. The compressorwill automatically restart after themotor cools,

Before First Start-up

_ Serious damagemay result if the

following break-in instructions are

not closely followed.

This procedure is required before theair compressor is put into service and

when the check valve or a completecompressor pump has beenreplaced.

1. Make sure the On/Auto/Off lever

is in the "OFF" position.

NOTE; If quick connect is installed,pull coupler back until it clicks to provent air from escaping through thequick connect.

2. Plug the power cord into the cor-rect branch circuit receptacle,(Refer to Voltage and CircuitProtection paragraph in theInstallation section of this manu-

al .)

3. Open the drain valve fully (coun-terclockwise) to permit air toescape and prevent air pressurebuild up in the air tank during thebreak-in period.

NOTE; Always drain tank on a wash-able surface or in a suitable container

to prevent damaging or staining sur-faces.

D24588 14 ENG

4. Move the On/Auto/Off lever to

"ON/AUTO" position. The com-pressor will start.

5. Run the compressor for 15 min-utes. Make sure the drain valve is

open and there is minimal airpressure build-up in tank

6, After 15 minutes, close the drain

valve (clockwise). The air receiverwill fill to "cut-out" pressure andthe motor will stop.

The compressor is now ready for use,

Before Each Start-Up:

1. Place On/Auto/Off lever to"OFF".

.

.

Pull regulator knob out, turn

counterclockwise until it stops.Push knob in to lock in place.

Attach hose and accessories.

NOTE: The hose or accessory

will require a quick connect plugif the air outlet is equipped with a

quick connect.

Too much air pres-sure causes a haz-

ardous risk of bursting. Check themanufacturer's maximum pressurerating for air tools and accessories.The regulator outlet pressure mustnever exceed the maximum pres-sure rating,

How to Start:

1, Turn the On/Auto/Off lever to

"AUTO" and allow tank pressureto build. Motor will stop whentank pressure reaches "cut-out"pressure.

2. Pull the regulator knob out andturn clockwise to increase pres-sure. When the desired pressure

is reached push knob in to lockin place. The compressor isready for use.

NOTE: Always operate the air com-pressor in well-ventilated areas free

of gasoline or other combustiblevapors. If the compressor is beingused to operate a sprayer DO NOTplace near the spray area.

15-ENG D24588

Customer Responsibilities

Before Daily orafter Every Every

each each 40 100use use hour's 30u_

Yearly I

Check Safety Valve •

Drain Tank •

Air Filter •(1) •

Air compressor pump intakeand exhaust valves •

1- more frequent in dusty or humid conditions

Unit cycles auto-matically when

power is on. When performingmaintenance, you may be exposedto voltage sources, compressedair, or moving parts. Personalinjuries can occur. Before perform-ing any maintenance or repair, dis-connect power source from thecompressor and bleed off all airpressure.

To ensure efficient operation andlonger life of the air compressor out-fit, a routine maintenance schedule

should be prepared and followed.The following routine maintenance

schedule is geared to an outfit in anormal working environment operat-

ing on a daily basis. If necessary, theschedule should be modified to suit

the conditions under which yourcompressor is used. The modifica-tions will depend upon the hours ofoperation and the working environ-ment. Compressor outfits in an

extremely dirty and/or hostile environ-ment will require a greater frequencyof all maintenance checks.

NOTE: See "Operation" section forthe location of controls.

D24588

To Check Safety Valve

If the safety valvedoes not work

properly, over-pressurization mayoccur, causing air tank rupture oran explosion.

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 Drain Tank

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

2. Pull the regulator knob out andturn clockwise to set the outlet

pressure to zero.

3. Remove the air tool or accesso-

ry.

4. Pull ring on safety valve allowingair to bleed from the tank until

tank pressure is approximately20 psi. Release safety valve ring.

5. Drain water from air tar_k byopening drain valve (counter-clockwise) on bottom of tank.

I_"Jffl=_"_l Water will con-dense in the air

tank. if not drained, water will cor-rode and weaken the air tank caus-

ing a risk of air tank rupture.

36- ENG

. After the water has been drained,

close the drain valve (clockwise).The air compressor can now bestored.

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

Air Filter Inspection and

Replacement

Hot surfaces. Riskof bum.

Compressor heads are exposedwhen filter cover is removed.

Allow compressor to cool prior to

servicing.

A dirty air filter will not allow the com-

pressor to operate at full capacity.Keep the air filter clean at all times.

1. Remove the air filter retainer.

2. Remove the air filter and makesure it is clean.

IMPORTANT: Do not operate thecompressor with the air filterremoved.

3. If dirty, rinse air filter with warmwater and squeeze dry.

4. Replace air filter and air filterretainer.

NOTE: If the air filter is extremelydirty it will need to be replaced. Refer

to the "Repair Parts" for the correctpart number.

Air Compressor Pump Intakeand Exhaust Valves

Once a year have a Trained ServiceTechnician check the air compressor

pump intake and exhaust valves.

Filter

17- ENG e24588

_Unit cycles auto-matically when

power is on. When doingMaintenance, you may be exposed

to voltage sources, compressed airor moving parts. Personal injuriescan occur. Before performing anyMaintenance or repair, unplug thecompressor and bleed off all air

pressure.

ALL MAINTENANCE AND REPAIROPERATIONS NOT LISTED MUSTBE PERFORMED BY A TRAINED

SERVICE TECHNICIAN.

_ Before servicing:

- Unplug or disconnect electricasupply to the air compressor,

• Bleed tank of pressure.• Allow the air compressor to

cool.

To Replace or Clean CheckValve

1. Release all air pressure from airtank. See "To Drain Tank" in theMaintenance section.

2. Unplug outfit.

3. Remove shrouds.

4. Using an adjustable wrench,loosen outlet tube nut at air tank

and pump. Carefully move outlettube away from check valve.

5. Using an adjustable wrench,

loosen pressure relief tube nut at

air tank and pressure switch.

Carefully move pressure relief

tube away from check valve.

6. Unscrew the check valve (turn

counterclockwise) using a 7/8"

open end wrench. Note the ori-entation for reassembly.

7. Using a screwdriver, carefully

push the valve disc up anddown. NOTE; The valve disc

should move freely up and down

on a spring which holds the valve

disc in the closed position; if not

the check valve needs to be

cleaned or replaced.

positionnothing isvisible.

In closed positiondisc is visible.

8. Clean or replace the check valve.A solvent, such as paint or var-nish remover can be used toclean the check valve.

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

10. Replace the pressure releasetube. Tighten nut.

11. Replace the outlet tube andtighten nut.

12. Replace the shroud and air filter

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

D24588 18-ENG

To Replace Regulator

1, Release all air pressure from airtank. See "To Drain Tank" in theMaintenance section.

2. Unplug air compressor.

3. Remove the outlet pressuregauge and quick connect (ifequipped) from the regulator.

4. Remove the regulator.

Gauge

6, Assemble the regulator and ori-ent as shown.

NOTE: Arrow indicates flow of air.

Make sure it is pointing in the direc-tion of air flow.

, Apply pipe sealant tape to thenipple.

Reg_

.

.

Reapply pipe sealant to outletpressure gauge and quick con-nect.

Reassemble outlet pressuregauge and quick connect. Orientoutlet pressure gauge to readcorrectly. Tighten quick connectwith wrench.

19-ENG D24588

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

1. Review the "Maintenance" sec-

tion on the preceding pages andperform scheduled maintenance

as necessary.

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

3. Turn the regulator counterclock-wise and set the outlet pressureto zero.

4 Remove the air tool or accesso-

ry.

5. Pull ring on safety valve allowingair to bleed from the tank until

tank pressure is approximately20 psi. Release safety valve ring,

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

Water will con-dense in the air

tank. If not drained, water will cor-rode and weaken the air tank caus-

ing 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 electrical cord and air

hose from damage (such asbeing stepped on or run over).Wind them loosely around thecompressor handle. (If so

equipped)

Store the air compressor in a cleanand dry location.

D24588 20 ENG

Performing repairs may expose voltage sources, movingparts or compressed air sources, moving parts or com-

pressed air sources. Personal injury may occur. Prior to attempting anyrepairs, unplug the air compressor and bleed off all air tank air pressure.

PROBLEM CAUSE CORRECTION

Excessive tank

pressure - safetyvalve pops off.

,, i

Air leaks at fit-

tings.

Air leaks at orinside checkvalve

Air leaks at

pressure switchrelease valve.

Air leaks in airtank or at airtank welds,

Air leaksbetween head

and valve plate.

Pressure switch does notshut off motor when com-)ressor reaches "cut-out"3ressure.

Pressure switch "cut--out"

too high.ii i.,

Tube fittings are not tightenough.

Check valve seat damaged.

Defective pressure switchrelease valve.

Defective air tank.

Leaking seal.

Move On/Auto/Off lever to

the "OFF" position, if theoutfit does not shut off con-tact a Trained Service

Technician.

Contact a Trained ServiceTechnician.

Tighten fittings where air can

be heard escaping. Checkfittings with soapy watersolution. Do Not

Overti_lhten.

A defective check valveresults in a constant air leak

at the pressure release valvewhen there is pressure in the

tank and the compressor isshut off. Replace checkvalve, Refer to the "To

Replace or Clean CheckValve" in the "Service and

Adjustment" section.

Contact a Trained ServiceTechnician,

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

Do not drill into, weld or

otherwise modify air tankor it will weaken. The tank

can rupture or explode.

Contact a Trained ServiceTechnician.

21- ENG 024588

CAUSE

It is normal for "some" pres-sure drop to occur.

ii

PROBLEM

Pressure reading

on the regulatedpressure gaugedrops when anaccessory is

used.

Knocking Noise.

Compressor isnot supplyingenough air to

operate acces-sories.

Possible defect in safetyvalve.

Defective check valve,

Prolonged excessive use ofair.

Compressor is not largeenough for air requirement.

Hole in hose.

Check valve restricted.

Air leaks.

Restricted air intake filter

CORRECTION

If there is an excessive

amount of pressure dropwhen the accessory is used,adjust the regulator followingthe instructions in the

"Description of Operation"paragraph in the "OperationSection.

NOTE: Adjust the regulated3ressure under flow condi-

tions (while accessory is

bein 9 used).

Operate safety valve manual-ly by pulling on ring. If valvestill leaks, it should bereplaced.

Remove and clean, orreplace.

Decrease amount of air

usage.

Clean or replace air intake fil-ter. Do not operate the aircompressor with the filterremoved. Refer to the "Air

Filter" paragraph in the"Maintenance " section.

Check the accessory air

requirement. If it is higherthan the SCFM or pressuresupplied by your air com-#ressor, you need a largercompressor.

Check and replace ifrequired.

Remove and clean, or

replace.

Tighten fittings.

Regulator knob Damaged regulator Replacehas continuousair leak.

D24568 22- ENG

PROBLEM

Regulator willnot shut off airoutlet.

_lotor will not

run

CAUSE

Damaged regulator

Motor overload protectionswitch has tripped

Tank pressure exceeds pres-sure switch "cut-in" pressure.

Extension cord is wronglength or gauge,

Check valve stuck open.

Loose electrical connections

Possible defective motor or

starting capacitor.

Paint spray on internal motor_arts.

Pressure release valve on

3ressure switch has not

unloaded head pressure.

Fuse blown, circuit breakertripped.

i

CORRECTION

Replace

:= , ,

Let motor cool off and over

load switch will automaticallyreset,

Motor will start automaticallywhen tank pressure dropsbelow "cut-in" pressure of

i pressure switch,

Check for proper gauge wireand cord length.

Remove and clean, or

replace.

Check wiring connectioninside pressure switch andterminal box area,

Have checked by a TrainedService Technician.

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

Bleed the line by pushing thelever on the pressure switchto the "off" position; if thevalve does not open, replaceswitch.1. Check fuse box for blown

fuse and replace as neces-sary. Reset circuit breaker.Do not use a fuse or circuitbreaker with higher ratingthan that specified for yourparticular branch circuit.

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

3. Check for low voltage con-ditions and/or properextension cord.

4. Disconnect the other elec-trical appliances from cir-cuit or operate the com-pressor on its own branchcircuit.

23-ENG O24588

Air Compressor Model Number 919.165190

/2

9-12 FI-_

36!

3O

7f

1

25

24J _

D24588 24-ENG

Air Compressor Model Number 919.165190

KEY

NO. PART NO.1 ACG-4082 CAC-13173 918956804 ACG-185 CAC-13736 CAC-13728 AC 06099 SSP-6021

10 SSW-736711 Z-D2300414 Z-AC-074615 TIA-415016 SSW-738517 SUDL-413-218 SS-1286

19 SSP-48021 AC -063022 CAC-4296-123 H-209924 AC 043025 Z-TA-4449-126 SSP-781127 AC-063128 SSF-98130 AC-002931 SSP-781332 AC-077433 AC-029234 SSP-7821-1

35 SSG -310536 D2422945 LA-306946 LA-302747 LA-310848 SST-1 O749 SSF-63051 D2313852 CAC-6053 SSF-8080-ZN

aS_6 aP_ZLO_ Assembly Fastener (3 used)Front ShroudScrew 1/4 - 20 x .75" (2 used)Saddle Mount Cup (2 used)Filter RetainerFoam Filter

Handle_Bushing Reducer 1/8 - 1/4 NPTStrain Relief Bushing

Gauge (2 used)Pressure Switch

Safety ValveStrain ReUef BushingCord Assembly

Nipple !/4-18 NPTNipple 1/4-18 NPT x 2.50Pressure Relief Tube

RegulatorAdapter 1/4 NPr x 1/4 NPSDrain ValveTank 25 GallonNut Sleeve Assembly 1/4" (2 used)Check Valve

Screw Hex (4 used)Rear Shroud

Nut Sleeve Assembly 3/8"Isolator (3 used)Outlet Tube

Nut Tubing 3/8"O-R_ng

Pump AssemblyLabel, Craftsman

Label, Drain Tank Eng/SpaLabel, Hot SurfaceRecess Rubber Bumper (2 used)

Screw (2 used)Wheel 9" (2 used)Shoulder Bolt 3/8 - 16UNC (2 used)

Hex Nut 3/8 - 16UNC-2B (2 used)

25 ENG D24588

Air Compressor Model Number 919.165190

85 Torque 7-10 Ft-Lbs

79-2

Torque ]00-120 In-Lbs

D24588 26-ENG

Air Compressor Model Number 919.165190

KEY

NO. PART NUMBER70 SSF-58672 AC-010873 SSF-615

74 Z-AC-014076 Z-D24228

>x78>x 79

>x 79-2 CAC-248-2> 79-3 ACG-29>x79-4 SSF-3158-1>x 80 SSG-8156

81 Z-AC-0032

82 CAC-1371>× 83 ACG-45

84 AC-003785 SSF-927

Not IllustratedD24588

x K-0650> KK-4835

DESCRIPTIONScrew 1/4-20 UNC x ,75Fan

Screw 1/4-20 UNC-2A

Eccentric BearingMotor

Cylinder Sleeve

Connecting Rod AssemblyFormed Compression RingConnecting Rod CapScrew 10-24 x .75 T25

O-Ring 2.759/2.7191D .073/.067W

Valve Plate AssemblyMuffler

O-RingHeadScrew 1/4-20 1 125 THD

Owner's Manual

Compression Ring KitConnecting Rod Kit

27-ENG D24588