ASEDeals Contractor Series Air Compressor Instruction Manual

Safety is a combination of common sense, staying alert, and knowing how your compressor works. Read this manual to understand this compressor.
DANGER
means if the safety information is not followed someone will be seriously injured or killed
WARNING
means if the safety information is not followed someone could be seriously injured or killed
CAUTION
means if the safety information is not followed someone may be seriously injured or killed
IMPORTANT SAFETY INSTRUCTIONS
Save these instructions
Improper operation or maintenance of this product could result in serious injury and property damage. Read and understand all warnings and operation Instructions before using this compressor.

Before using the air compressor

Things you should know
Air compressors are utilized In a variety of air system applications. Because air compressors and other components (hoses, connectors, air tools, spray guns, etc.) make up a high-pressure pumping system, the following safety precautions should be observed at all times.
Only persons familiar with these rules of safe operation should use the air compressor.

Read the instruction manual carefully before attempting to assemble, disassemble or operate your system. Be thoroughly familiar with the controls and the proper use of the equipment.
Review and understand all safety instructions and operating procedures in this manual.
Review the maintenance methods for this compressor (See ‘Maintaining Your Compressor” section).

Inspect your work area

Keep work area clean.
Cluttered areas and benches invite accidents. Floors must not be slippery from wax or dust.

Inspect your compressor

To reduce the risk of injury from accidental starting, turn the switch off and disconnect the power before checking it.
If any part is missing, bent, or broken in any way, or any electrical part does not work properly, keep the compressor off and disconnected.
Check hoses for weak or worn conditions before each use, making certain all connections are secure. Do not use it if a defect is found.

WARNING
Do not operate the compressor if damaged during shipping, handling, or use. Damage may result In bursting and cause Injury or property damage.
DANGER
This compressor is not designed for and should not be used in breathing air applications.

When Installing or moving the compressor

WARNING
This compressor is extremely top-heavy.
To reduce the risk of a dangerous environment

Keep work area well lit.
Operate compressor in a well-ventilated area free from flammable liquids and vapors.
Operate the compressor in a ventilated area so that compressor may be properly cooled and the surrounding air temperature will not be more than 100°F.
Never use a compressor in a wet environment.
Protect material lines and airlines from damage or puncture. Keep hoses and wires away from sharp objects, chemical spills, oil, solvents, and wet floors.
WARNING
Do Not secure compressor with toggle bolts into drywall. Drywall sheeting or plaster will not support the weight of the compressor.
Always Shut Off Gas Valve before moving Gas Drive Compressors|
A minimum clearance of 18 Inches between the compressor and a wall Is required because objects could obstruct airflow.
The compressor should be located where It can be directly wired to a circuit breaker. The compressor should be wired by a qualified electrician.
Never store flammable liquids or gases in the vicinity of an operating compressor.
Do Not locate the compressor air inlet near the steam, paint spray, sandblasting areas, or any other source of contamination. The debris could damage the motor and pump.

WARNING
Never use plastic (PVC) pipes for compressed air. Serious injury or death could result.
CAUTION
Never use the shipping pallet for mounting the compressor.
NOTICE
Electric Compressors are not suitable for outdoor installation.
NOTICE
Gasoline Compressors must be operated outdoors, sheltered from the weather.
WARNING
Never install a shut-off valve between the compressor pump and tank. Personal injury and/or equipment damage could occur.

Before each use

Inspect your work area

Keep work area dean. Cluttered areas and benches invite accidents.
The floor must not be slippery from wax or dust.

Inspect your compressor

To reduce the risk of injury from accidental starting, tum the switch off and disconnect VOWEK
If any part Is missing, bent, or broken In any way, or any electrical part does not work properly, keep the compressor off and disconnect power. Do Not use it if a defect is found.
Check hoses for weak or wom condition before each use, making certain all connections are secure. Do Not use it if a defect is found.

Follow the safety precautions for electrical connections

Follow all local electrical and safety codes, as well as the National Electric Code (NEC) and the Occupational Safety and Health Act (OSHA).
Wiring and fuses should follow electrical codes, and current capacity and be properly grounded.
Protect wires from contact with sharp objects.

CAUTION
All electrical connections should be made by a qualified electrician.

Plan ahead to protect your eyes, hands, face, and ears

Dress for safety

Wear safety glasses (meeting ANSI Z87.1 or in Canada CSA Z94.3-99) and use hearing protection when operating the unit. Everyday glasses are not safety glasses.
Wear shoes to prevent shock hazards.
Tie back long hair.

Pay attention to your hands
WARNING
Keep fingers away from running compressor. Fast-moving and hot parts may cause injury and/or bums.
WARNING
Be careful when touching the exterior of compressor, pump, motor, and airlines: they may become hot enough to cause injury.
WARNING
Never operate the compressor without a belt guard. The compressor can start automatically without warning. Personal injury or property damage could occur from contact with moving parts.
CAUTION
The compressor may be hot even if the unit is stopped.
WARNING
Use of a mask or respirator per chemical manufacturers’ instructions may be necessary if there is a chance of inhaling toxic fumes. Read mask and respirator instructions carefully. Consult a safety expert if you are not sure about the use of certain masks or respirators.

When operating

Do not exceed the pressure rating of any component of the system.
Release pressure within the system slowly to prevent flying dust and debris.
If the equipment starts to abnormally vibrate, STOP the compressor immediately and check for the cause.

WARNING
Never change the safety valve or pressure switch settings.
Keep safety valve free from paint and other accumulations. See compressor specification decal for maximum operating pressure.
Do not operate with the pressure switch set higher than the maximum operating pressure.

Spraying precautions

WARNING
Never point a spray gun at yourself or any other person or animal. Accidental discharge may result in serious injury.
Reduce the risk of the dangerous environment
WARNING
Extreme caution should be taken when spraying flammable liquids as the spark from a motor or pressure switch may cause a fire or explosion. Ample ventilation must be provided.
WARNING
Spray in a well-ventilated area to keep fumes from collecting and causing serious Injury and fire hazards.

Do Not spray in the vicinity of open flames or other places where a spark can cause ignition. Do Not smoke when spraying paint, insecticides, or other flammable substances.

Be Informed about the materials you use

When spraying with solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer. Consult a safety expert if unsure about the use of masks or respirators.
If the material you intend to spray contains trichloroethane and methylene chloride, do not use accessories that contain aluminum or galvanized materials, as these chemicals can react with galvanized components causing corrosion and weakening equipment. Use stainless steel accessories.

Perform these maintenance operations

Do regular maintenance; keep all nuts, bolts, and screws tight, to be sure equipment is in safe working condition.
Inspect the tank yearly for rust, pinholes, or any other imperfections that could cause it to become unsafe.
WARNING
NEVER attempt to repair or modify a tank! Welding, drilling, or any other modification will weaken the tank resulting in damage from rupture or explosion. Always replace worn, cracked, or damaged tanks.
Clean electrical equipment with an approved cleaning agent, such as a dry, nonflammable cleaning solvent.
Daily
Check oil level at the sight glass. The oil level should be 1/2 to slightly higher in the oil sight glass.
Drain moisture from the tank.
Verify the pressure switch unloader is working by listening for a brief hissing sound when the compressor shuts off.
Visually check the compressor for loose parts, excessive noise, or vibration. Tighten any necessary part.
Drain tanks of moisture after each day’s use. If the unit will not be used for a while, it is best to leave the drain cock open until such time as it is to be used. This will allow moisture to completely drain out and help prevent corrosion inside of the tank.
Always disconnect from the power source before working on or near a motor, or it’s connected If the power disconnect point is out-of-sight, secure it in the “OFF” position and tag it to prevent the unexpected application of power.

WARNING
Disconnect power and depressurize system before servicing air compressor. Slightly open the drain cock after shutting off the compressor.
Monthly
(Make sure the main power is off.) Check the belts for tension. Belts should not move up and down when the compressor runs and when stopped, should not have more than ‘% inch of play when depressed. Be careful not to over tighten belts during adjustment.
Remove and check the air filter, replace it if necessary.
Change oil every 3 months or 300 hours. A compressor grade 30 wt non-detergent oil should be used. 40 wt non-detergent for single stage.

GLOSSARY OF TERMS

Air Filter
Porous element contained within a metal or plastic housing attached to the compressor cylinder head removes impurities from the intake air of the compressor.
Air Tank
The cylindrical component contains compressed air.
Check Valve
A device which prevents compressed air from flowing back from the air tank to the compressor pump.
Electric Motor
A device that provides the rotational force necessary to operate the compressor pump.
Pressure Gauge
A device which shows the tank or regulated pressure of the compressed air
Pressure Switch
A device that automatically controls the on/off cycling of the compressor. It stops the compressor when the cut-off pressure in the tank is reached and starts the compressor when the air pressure drops below the cut-in pressure.
PSI (Pounds per Square Inch)
Measurement of the pressure exerted by the force of the air. The actual psi is measured by a pressure gauge on the compressor.
Pump
A device that produces compressed air with a reciprocating piston contained within a cylinder.
Safety Valve
A device that prevents air pressure in the air tank from rising over a predetermined limit.
Thermal Overload Switch
The device, integrated into the electric motor winding, which automatically “shuts off the compressor if the temperature of the electric motor exceeds a predetermined limit.

WIRING

STARTING THE COMPRESSOR

Prior to actually running the compressor, check the following items:
Crankcase oil – Make sure the sight glass shows ‘h full or slightly above.
Make sure all rags, tools, oil, etc. are away from the unit.
Open the air system to free it of any pressure.
Switch the compressor on for a few revolutions to make sure the rotation is correct. Correct rotation is clockwise when facing the sight glass on the pump.
Operate the compressor for a few minutes unloaded (air system open) then allow the compressor to pump up. Make sure the electrical pressure switch properly switches off the compressor according to the setting
desired. Confirm maximum psi as indicated on the unit data plate.
CAUTION
Make sure the pressure in the tank does not exceed its rating. Confirm maximum psi as indicated on the unit data plate. If the pressure gauge indicates a pressure that is higher than the stated maximum pressure shut off the compressor immediately and call your distributor.
(Gas Drive Models)
PLEASE REFER TO YOUR ENGINE OPERATION MANUAL FOR PROPER STARTING INSTRUCTIONS.
GASOLINE-DRIVEN COMPRESSORS ARE EQUIPPED WITH A COLD START VALVE FOR LOAD STARTS.
NOTE: IN SOME INSTANCES, IT STILL
MAY BE NECESSARY TO LIFT THE TOGGLE ON THE UNLOADER/PILOT VALVE TO RELIEVE THE HEAD PRESSURE.
Cold Start Procedure (Gasoline Engine Units)
Throttle control
Warning:
Do Not Operate Gasoline Engine
Units in an Enclosed Area

Release any remaining tank pressure by slowly opening the manual drain
Turn on the engine gasoline supply.
Put the choke in the “On” position.
Close the service valve and put the Unloader lever in the “unload” (A) position for Honda engine-driven models.
Start the engine, release the choke, and allow the engine to warm up for two to three minutes.
Return the unloader lever to the “load” (B) position on Honda-driven models.

Note: Turn the gasoline supply off when the compressor is not being used

TROUBLESHOOTING GUIDE

Low discharge pressure	Compressor too small for the application Air leaks Restricted intake air Blown gasket(s) Broken or misaligned valves	Reduce air demand capacity. Listen for air leaks. connections. Apply a soap solution to all fittings and will form at points of leakage. Tighten connections filter. Bubbles for broken or misaligned valves. or use a compressor with more air or replace fittings or connections Clean or replace air Replace necessary gaskets. Remove head and inspect CAUTION Replace valves, if necessary. Install a new head gasket each time head is removed
Excessive noise ‘knocking’	Loose drive pulley or flywheel Low on oil Worn connecting rod or connecting rod bearing Noisy check valve	Tighten the drive pulley or flywheel bolt. Check for proper oil level. Low or dirty oil may cause bearing rod and/or connecting rod bearings damage. Replace connecting Replace the check valve. DANGER Do not remove the check valve with air pressure in the tank
Excessive oil carryover	Worn piston rings Restricted intake air Too much oil in the compressor Incorrect oil viscosity	Replace with new piston rings. Clean or replace the air filter. Drain oil to the proper oil level. Use a quality non-detergent 30 or 40w4 oil specified for each model (Page 4).
Water in the tank and/or discharge line	Normal. The amount of water will increase as humidity in the air increases.	Drain tank at least once per day. Add an inline filter to reduce moisture in the airline.
Will not run or motor hums	Low voltage Malfunctioning pressure switch Malfunctioning check valve	Check voltage with power. Check reset voltmeter across both legs of an incoming button on the motor. Repair or replace the pressure switch. Replace the check valve or pressure switch. DANGER Do not remove the check valve with air pressure in the tank
Breaker or reset repeatedly trips	Incorrect breaker size Low voltage Malfunctioning motor Loose electrical connections Malfunctioning pressure switch Malfunctioning check valve	Make sure the breaker manual. Check voltage is sized properly. See page 6 in this voltmeter across both legs of incoming power. Replace motor. Check all electrical connections. Adjust or replace the pressure switch. Replace the check valve. DANGER Do not remove the check valve with air pressure in the tank
The tank does not hold pressure when not running and shut off valve is closed	Malfunctioning check valve Loose fittings or connections Crack or pinhole in the tank	Replace check valve DANGER Do not remove check valve with air pressure in the tank Tighten or replace fittings or connections. Replace tank. Do not attempt to repair tank.
The pressure switch unloader constantly leaks air	Malfunctioning check valve	Replace check valve if unloader bleeds constantly. DANGER Do not remove the check valve with air pressure in the tank
Pressure switch not unloading _	1. Malfunctioning pressure switch	Replace the pressure switch if it does not release air pressure briefly when the unit shuts off. DANGER Do not remove the pressure switch with air pressure in the tank
Excessive vibration	Improper installation Loose belts Misaligned flywheel or drive pulley	Make sure the unit is mounted on a level surface with vibration pads. Replace belts. Align and tighten properly. Align flywheel and drive pulley.
Overheating	Compressor too small for the application Cooling surfaces dirty Improper cooling	Reduce air demand or use a compressor with more air capacity. Clean all cooling surfaces of dirt and dust. Install compressor in an area with adequate cool dry air.

Pump Specifications

Pump Model	Cvl. No.	States
PAT24	2	1
PAT38	2	1

Pump Model	Cyl. Diam. In. (mm)		Stroke in. (mm)	Max rpm	Oil Cap. Qt. (L)	Displacement @ max RPM
Pump Model	1st St g	2nd St g	Stroke in. (mm)	Max rpm	Oil Cap. Qt. (L)	CFM	UM
PAT24	2.48 (63)	N/A	1.50 (38)	1400	.56 (0.53)	11.71	331.59
PAT38	2.48 (63)	N/A	2.36 (60)	j 1400	.91 (.86)	18.49	523.58

Pump Model	Bolt Torque Ft.-Lbs. (NM)
Pump Model	Conrod	Head	Cylinder	Bearing Housing	Flywheel
PAT24	N/A	118-20 (24-27)	18-20 (24-27)	6.5-8.1( 9-11)	118-20 (24-27)
PAT38	N/A	118-20 (24-27)	18-20 (24-27)	6.5-8.1( 9-11)	118-20 (24-27)

Tank Specifications

Volume		Max Pressure		Discharge Conn.
Gal.	Liter	PSI	Bar	NPT
24V	91	175	12.069	Coupling G1/4 M USA
24H	91	175	12.069	Coupling G1/4 M USA
2X4	2X15.2	200	13.793	3/8″

WARNING
Oil and moisture residue must be drained from the air receiver daily or after each use. Accumulation of oil residue in the receiver can be ignited by embers of carbon created by the heat of compression – causing an explosion, damage to property, and injury to personnel.
WARNING
Do not open a manual tank drain valve on any air tank containing more than 30 PSIG of air pressure!
WARNING
Never attempt to relieve an air tank by removing a pipe plug or any other system component!
Manually Draining an Air Tank:
Step 1
Disconnect & lock out the compressor from the power source (electric models) or disconnect the spark plug wire from the spark plug (gas engine models).
Step 2
Tank(s) subjected to freezing temperatures may contain ice. Store the compressor in a heated area before attempting to drain moisture from the tank(s). Reduce the air pressure in the tank to 30 PSIG by pulling the pressure relief valve ring.
Step 3
Slowly open the drain valve and allow the moisture and air mixture to drain from the tank.
Step 4
Once the moisture has been completely drained, close the drain valve.
Air Tank Inspection

Tank Capacity	Horizontal _{or Vertical}	Minimum Allowable Wall		Usually, Inspect	Hydrostatically Inspect
Tank Capacity	Horizontal _{or Vertical}	HEAD	SHELL	Usually, Inspect	Hydrostatically Inspect
8 Gal.	Twin Horiz.	0.079	0.079	Yearly	10 Years
24 Gal.	Horizontal	0.094	0.094	Yearly	10 Years

Recommended Air Tank Inspection Intervals
The factory recommends that all air tanks be inspected at scheduled intervals. Refer to Recommended Air Tank Inspection Intervals Table for relative information.
Refer to federal, state or provincial, or local codes for mandatory air tank maintenance information.

Warranty Statement

The Company warrants that the Equipment manufactured by it and delivered hereunder shall be free from defects in material and workmanship for a period of twelve (12) months from the date of initial start-up, or eighteen (18) months from the date of shipment from the manufacturer, whichever occurs first. The foregoing warranty period shall apply to all Equipment, except for the following: (A) all two-stage reciprocating stationary models are warranted for the earlier of twenty-four (24) months from the date of initial operation or thirty (30) months from the date of shipment from the manufacturer. (B) Replacement parts will be warranted for three (3) months from the date of shipment from the manufacturer. Should the failure to conform to this warranty be reported in writing to the Company within the said period, the Company shall, at its option, correct such non-conformity by suitable repair to such Equipment, or furnish a replacement part F.O.B point of shipment, provided that the Purchaser has installed, maintained, and operated such Equipment in accordance with good industry practices, and has complied with specific recommendations of the Company. Accessories and equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturer conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment, or any costs of labor performed by the Purchaser without the Company’s prior written approval.
The Company makes no performance warranty unless specifically stated within its proposal, and the effects of corrosion, erosion, and normal wear and tear are specifically excluded from the Company’s warranty. In the event performance warranties are expressly included, the Company’s obligation shall be to correct in the manner and for the period of time provided above.
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. THIS WARRANTY SUPERSEDES ALL PREVIOUS WARRANTY STATEMENTS.
Correction by the Company of non-conformities, whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of the Company and its distributors for such non-conformities with respect to, or arising out of such Equipment.
LIMITATION OF LIABILITY
THE REMEDIES OF THE PURCHASER SET FORTH HEREIN ARE EXCLUSIVE, AND THE TOTAL LIABILITY OF THE COMPANY, ITS DISTRIBUTORS, AND SUPPLIERS WITH RESPECT TO CONTRACT OR THE EQUIPMENT AND SERVICES FURNISHED IN CONNECTION WITH THE PERFORMANCE OR BREACH THEREOF, OR FROM THE MANUFACTURE, SALE, DELIVERY, INSTALLATION, REPAIR OR TECHNICAL DIRECTION COVERED OR FURNISHED UNDER CONTRACT, WHETHER BASED ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE, SHALL NOT EXCEED THE PURCHASE PRICE OF THE EQUIPMENT UPON WHICH SUCH LIABILITY IS BASED.
THE COMPANY, ITS DISTRIBUTORS, AND ITS SUPPLIERS SHALL IN NO EVENT BE LIABLE TO THE PURCHASER, ANY SUCCESSORS IN INTEREST, OR ANY BENEFICIARY OR ASSIGNEE OF THE CONTRACT FOR ANY CONSEQUENTIAL, INCIDENTAL, INDIRECT, SPECIAL, OR PUNITIVE DAMAGES ARISING OUT OF THIS CONTRACT OR ANY BREACH THEREOF, OR ANY DEFECT IN, OR FAILURE OF, OR MALFUNCTION OF THE EQUIPMENT, WHETHER OR NOT BASED ON LOSS OF USE, LOST PROFITS OR REVENUE, INTEREST, LOST GOODWILL, WORK STOPPAGE, IMPAIRMENT OF OTHER GOODS, LOSS BY REASON OF SHUTDOWN OR NON-OPERATION, COST OF PURCHASE OF REPLACEMENT POWER, OR CLAIMS OF PURCHASER OR CUSTOMERS OF PURCHASER FOR SERVICE INTERRUPTION, WHETHER OR NOT SUCH LOSS OR DAMAGE IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE.

SAFETY GUIDELINES – DEFINITIONS