Porter-Cable CPLDC2540P User's Manual
Contents
1. IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS INJURY AND PROPERTY DAMAGE READ AND UNDERSTAND ALL WARNINGS AND OPERATING INSTRUCTIONS BEFORE USING THIS EQUIPMENT HAZARD RISK OF EXPLOSION OR FIRE WHAT CAN HAPPEN IT IS NORMAL FOR ELECTRICAL CONTACTS WITHIN THE MOTOR AND PRESSURE SWITCH TO SPARK IF ELECTRICAL SPARKS FROM COMPRESSOR COME INTO CONTACT WITH FLAMMABLE VAPORS THEY MAY IGNITE CAUSING FIRE OR EXPLOSION RESTRICTING ANY OF THE COMPRESSOR VENTILATION OPENINGS WILL CAUSE SERIOUS OVERHEATING AND COULD CAUSE FIRE UNATTENDED OPERATION OF THIS PRODUCT COULD RESULT IN PERSONAL INJURY OR PROPERTY DAMAGE TO REDUCE THE RISK OF FIRE DO NOT ALLOW THE COMPRESSOR TO OPERATE UNATTENDED 3 ENG HOW TO PREVENT IT ALWAYS OPERATE THE COMPRESSOR IN A WELL VENTILATED AREA FREE OF COMBUSTIBLE MATERIALS GASOLINE OR SOLVENT VAPORS IF SPRAYING FLAMMABLE MATERIALS LOCATE COMPRESSOR AT LEAST 20 FEET AWAY FROM SPRAY AREA AN ADDITIONAL LENGTH OF HOSE MAY BE REQUIRED STORE FLAMMABLE MATERIALS IN A SECURE LOCATION AWAY FROM COMPRESSOR NEVER PLACE OBJECTS AGAINST OR ON TOP OF COMPRESSOR OPERATE COMPRESSOR IN AN OPEN AREA AT LEAST 12 INCHES AWAY FROM ANY WALL OR OBSTRUCTION THAT WOULD RESTRICT THE FLOW OF FRESH AIR TO THE VENTILATION OPENINGS OPERATE COMPRESSOR IN A CLEAN DRY WELL VENTILATED AREA DO NOT OPERATE UNIT INDOORS OR IN ANY CONFINED AREA ALWAYS2. if equipped Air leaks in air tank or at air tank welds Air leaks between head and valve plate A02231 TROUBLESHOOTING Performing repairs may expose voltage sources moving parts or compressed air sources moving parts or compressed air sources Personal injury may occur Prior to attempting any repairs unplug the air compressor and bleed off all air tank air Pressure switch does not shut off motor when compressor reaches cut out pressure Pressure switch cut out too high Tube fittings are not tight enough Check valve seat damaged Defective pressure switch release valve Defective air tank Leaking seal 20 ENG CORRECTION Move On Auto Off lever to the OFF position if the outfit does not shut off contact a Trained Service Technician Contact a Trained Service Technician Tighten fittings where air can be heard escaping Check fittings with soapy water solution DO NOT OVERTIGHTEN A defective check valve results in a constant air leak at the pressure release valve when there is pressure in the tank and the compressor is shut off Contact a Trained Service Technician to replace check valve Contact a Trained Service Technician Air tank must be replaced Do not repair the leak Do not CAUSE dri into weld or otherwise modify air tank or it will weaken The tank can rupture or explode Contact a Trained Service Technician PROBLEM CAUSE
3. OF THIS PRODUCT EQUIP AREA OF OPERATION WITH A FIRE EXTINGUISHER DO NOT OPERATE MACHINE WITH MISSING BROKEN OR UNAUTHORIZED PARTS A02231 GLOSSARY Become familiar with these terms before operating the unit CFM Cubic feet per minute SCFM Standard cubic feet per minute a unit of measure of air delivery PSIG Pounds per square inch gauge a unit of measure of pressure Code Certification Products that bear one or more of the following marks UL CUL ETL CETL have been evaluated by OSHA certified independent safety laboratories and meet the applicable Underwriters Laboratories Standards for Safety Cut In Pressure While the motor is off air tank pressure drops as you continue to use your accessory When the tank pressure drops to a certain low level the motor will restart automatically The low pressure at which the motor automatically restarts is called cut in pressure Cut Out Pressure When an air compressor is turned on and begins to run air pressure in the air tank begins to build It builds to a certain high pressure before the motor automatically shuts off protecting your air tank from pressure higher than its capacity The high pressure at which the motor shuts off is called cut out pressure Branch Circuit Circuit carrying electricity from electrical panel to outlet DUTY CYCLE Porter Cable air compressors should be operated on not more than a 50 duty cycle This means an air compressor that
4. OUTDOORS WHEN IT IS RAINING OR IN WET CONDITIONS NEVER OPERATE COMPRESSOR WITH PROTECTIVE COVERS REMOVED OR DAMAGED ANY ELECTRICAL WIRING OR REPAIRS REQUIRED ON THIS PRODUCT SHOULD BE PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL IN ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES MAKE CERTAIN THAT THE ELECTRICAL CIRCUIT TO WHICH THE COMPRESSOR IS INJURY OR DEATH FROM ELECTROCUTION CONNECTED PROVIDES PROPER SEE GROUNDING INSTRUCTIONS ELECTRICAL GROUNDING CORRECT VOLTAGE AND ADEQUATE FUSE PROTECTION HAZARD RISK TO BREATHING WHAT CAN HAPPEN THE COMPRESSED AIR DIRECTLY FROM YOUR COMPRESSOR IS NOT SAFE FOR BREATHING THE AIR STREAM MAY CONTAIN CARBON MONOXIDE TOXIC VAPORS OR SOLID PARTICLES FROM THE TANK BREATHING THESE CONTAMINANTS CAN CAUSE SERIOUS INJURY OR DEATH SPRAYED MATERIALS SUCH AS PAINT PAINT SOLVENTS PAINT REMOVER INSECTICIDES WEED KILLERS MAY CONTAIN HARMFUL VAPORS AND POISONS 5 ENG HOW TO PREVENT IT AIR OBTAINED DIRECTLY FROM THE COMPRESSOR SHOULD NEVER BE USED TO SUPPLY AIR FOR HUMAN CONSUMPTION IN ORDER TO USE AIR PRODUCED BY THIS COMPRESSOR FOR BREATHING SUITABLE FILTERS AND IN LINE SAFETY EQUIPMENT MUST BE PROPERLY INSTALLED IN LINE FILTERS AND SAFETY EQUIPMENT USED IN CONJUNCTION WITH THE COMPRESSOR MUST BE CAPABLE OF TREATING AIR TO ALL APPLICABLE LOCAL AND FEDERAL CODES PRIOR TO HUMAN CONSUMPTION WORK IN AN AREA WITH GOOD CROSS VENTILATION R
5. Place On Auto Off lever to OFF Pull regulator knob out turn counter clockwise until it stops Push knob in to lock in place Attach hose and accessories NOTE The hose or accessory will require a quick connect plug if the air outlet is equipped with a quick connect socket AWARNING Too much air pressure causes a hazardous risk of bursting Check the manufacturer s maximum pressure rating for air tools and accessories The regulator outlet pressure must never exceed the maximum pressure rating How to Start 1 Turn the On Auto Off lever to AUTO and allow tank pressure to build Motor will stop when tank pressure reaches cut out pressure Pull the regulator knob out and turn clockwise to increase pressure When the desired pressure is reached push knob in to lock in place The compressor is ready for use NOTE Always operate the air compressor in well ventilated areas free of gasoline or other combustible vapors If the compressor is being used to operate a sprayer DO NOT place near the spray area A02231 14 ENG MAINTENANCE Customer Responsibilities pay or Every Every Every Every ater g 40 160 Yearly each hours hours hours hours rain Tank il Leaks heck Oil hange Oil 1 more frequent in dusty or humid conditions ACAUTION Unit cycles automatically when power is on When performing maintenance you may be exposed to voltage sources compressed air or moving parts Pe
6. REMAIN IN ATTENDANCE WITH THE PRODUCT WHEN IT IS OPERATING ALWAYS DISCONNECT ELECTRICAL POWER BY MOVING PRESSURE SWITCH LEVER TO THE OFF POSITION AND DRAIN TANK DAILY OR AFTER EACH USE A02231 HAZARD RISK OF BURSTING M AIR TANK THE FOLLOWING CONDITIONS COULD LEAD TO A WEAKENING OF THE TANK AND RESULT IN A VIOLENT TANK EXPLOSION AND COULD CAUSE PROPERTY DAMAGE OR SERIOUS INJURY WHAT CAN HAPPEN 1 FAILURE TO PROPERLY DRAIN CONDENSED WATER FROM THE TANK CAUSING RUST AND THINNING OF THE STEEL TANK 2 MODIFICATIONS OR ATTEMPTED REPAIRS TO THE TANK 3 UNAUTHORIZED MODIFICATIONS TO THE UNLOADER VALVE SAFETY VALVE OR ANY OTHER COMPONENTS WHICH CONTROL TANK PRESSURE 4 EXCESSIVE VIBRATION CAN WEAKEN THE AIR TANK AND CAUSE RUPTURE OR EXPLOSION ATTACHMENTS amp ACCESSORIES EXCEEDING THE PRESSURE RATING OF AIR TOOLS SPRAY GUNS AIR OPERATED ACCESSORIES TIRES AND OTHER INFLATABLES CAN CAUSE THEM TO EXPLODE OR FLY APART AND COULD RESULT IN SERIOUS INJURY HOW TO PREVENT IT DRAIN TANK DAILY OR AFTER EACH USE IF TANK DEVELOPS A LEAK REPLACE IT IMMEDIATELY WITH A NEW TANK OR REPLACE THE ENTIRE COMPRESSOR NEVER DRILL INTO WELD OR MAKE ANY MODIFICATIONS TO THE TANK OR ITS ATTACHMENTS THE TANK IS DESIGNED TO WITHSTAND SPECIFIC OPERATING PRESSURES NEVER MAKE ADJUSTMENTS OR PARTS SUBSTITUTIONS TO ALTER THE FACTORY SET OPERATING PRESSURES FOR ESSENTIAL CONTROL OF AIR PRE
7. the amount of oil in the pump the mark indicates full and the mark indicates oil needs to be added See Oil paragraphs in the Maintenance section P for instructions KA Motor Thermal Overload Protector not shown The Dipstick 9 motor has an automatic reset thermal overload protector If the motor overheats for any reason the overload N protector will shut off the motor The motor must be MA allowed to cool down before restarting The compressor will automatically restart after the motor cools Air Intake Filter not shown This filter is designed to clean air coming into the pump This filter must always be clean and ventilation openings free from obstructions See Maintenance Check Valve When the air compressor is operating the check valve is open allowing a Pressure compressed air to enter the air tank When the Helens air compressor reaches cut out pressure the check valve closes allowing air pressure to remain inside the air tank Pressure Release Valve The pressure release valve located on the side of the pressure switch is designed to automatically release compressed air from the compressor head and the outlet tube when the air compressor reaches cut out pressure or is shut off The pressure release valve allows the motor to restart freely When the motor stops running air will be heard escaping from this valve for a few seconds No air should be heard leaking wh
8. which if not avoided may result in property damage IMPORTANT SAFETY INSTRUCTIONS AWARNING Some 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 other reproductive harm Some example of these chemicals are lead from lead based paints s 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 often you do this type of work To reduce your exposure to these chemicals work in a well ventilated area and work with approved safety equipment always wear MSHA NIOSH approved properly fitting face mask or respirator when using such tools When using air tools basic safety precautions should always be followed to reduce the risk of of personal injury READ AND FOLLOW ALL INSTRUCTIONS This tool was designed for certain applications Porter Cable strongly recommends that this tool NOT be modified and or used for any application other than for which it was designed If you have any questions relative to its application DO NOT use the tool until you have written Porter Cable and we have advised you Technical Service Manager Porter Cable Corporation 4825 Highway 45 North P O Box 2468 Jackson TN 38302 2468 A02231 2 ENG IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS
9. E 10 weight oil 6 Replace dipstick A Changing 1 Set the On Auto Off lever to OFF 2 Remove the dipstick A 3 Remove the oil drain plug B and drain oil into a suitable container 4 Replace the oil drain plug B A02231 16 ENG NOTE Use a air compressor oil such as SAE 30 API CG CD heavy duty motor oil Under extreme winter conditions use SAE 10 weight oil 5 Slowly fill crankcase with oil Crankcase capacity is 8 fluid ounces 236 6 ml Oil level should be at the full mark on the dipstick ACAUTION Overfilling with oil will cause premature compressor failure Do not overfill 6 Replace dipstick A Air Filter Inspection and Replacement AWARNING Hot surfaces Risk of burn Compressor heads are exposed when filter cover is removed Allow compressor to cool prior to servicing A dirty air filter will not allow the compressor to operate at full capacity Keep the air filter clean at all times 1 Remove the air filter cover 2 Remove the air filter from filter cover IMPORTANT Do not operate the compressor with the air filter removed 3 Place new air filter into filter cover Refer to the Repair Parts for the correct part number 4 Replace air filter cover and lock into place Motor The motor has an automatic reset thermal overload protector If the motor overheats for any reason the overload protector will shut off the motor The motor must be allowed to cool down before res
10. EAD AND FOLLOW THE SAFETY INSTRUCTIONS PROVIDED ON THE LABEL OR SAFETY DATA SHEETS FOR THE MATERIAL YOU ARE SPRAYING USE A NIOSH MSHA APPROVED RESPIRATOR DESIGNED FOR USE WITH YOUR SPECIFIC APPLICATION A02231 HAZARD RISK OF BURNS WHAT CAN HAPPEN TOUCHING EXPOSED METAL SUCH AS THE COMPRESSOR HEAD OR OUTLET TUBES CAN RESULT IN SERIOUS BURNS kr HOW TO PREVENT IT NEVER TOUCH ANY EXPOSED METAL PARTS ON COMPRESSOR DURING OR IMMEDIATELY AFTER OPERATION COMPRESSOR WILL REMAIN HOT FOR SEVERAL MINUTES AFTER OPERATION DO NOT REACH AROUND PROTECTIVE SHROUDS OR ATTEMPT MAINTENANCE UNTIL UNIT HAS BEEN ALLOWED TO COOL HAZARD RISK FROM MOVING PARTS WHAT CAN HAPPEN MOVING PARTS SUCH AS THE PULLEY FLYWHEEL AND BELT CAN CAUSE SERIOUS INJURY IF THEY COME INTO CONTACT WITH YOU OR YOUR CLOTHING ATTEMPTING TO OPERATE COMPRESSOR WITH DAMAGED OR MISSING PARTS OR ATTEMPTING TO REPAIR COMPRESSOR WITH PROTECTIVE SHROUDS REMOVED CAN EXPOSE YOU TO MOVING PARTS AND CAN RESULT IN SERIOUS INJURY HOW TO PREVENT IT NEVER OPERATE THE COMPRESSOR WITH GUARDS OR COVERS WHICH ARE DAMAGED OR REMOVED ANY REPAIRS REQUIRED ON THIS PRODUCT SHOULD BE PERFORMED BY AUTHORIZED SERVICE CENTER PERSONNEL HAZARD RISK OF FALLING WHAT CAN HAPPEN A PORTABLE COMPRESSOR CAN FALL FROM A TABLE WORKBENCH OR ROOF CAUSING DAMAGE TO THE COMPRESSOR AND COULD RESULT IN SERIOUS INJURY OR DEATH TO T
11. HE OPERATOR HOW TO PREVENT IT ALWAYS OPERATE COMPRESSOR IN A STABLE SECURE POSITION TO PREVENT ACCIDENTAL MOVEMENT OF THE UNIT NEVER OPERATE COMPRESSOR ON A ROOF OR OTHER ELEVATED POSITION USE ADDITIONAL AIR HOSE TO REACH HIGH LOCATIONS HAZARD RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR Fire Inhalation Damage to Vehicle Surfaces WHAT CAN HAPPEN OIL CAN LEAK OR SPILL AND COULD RESULT IN FIRE OR BREATHING HAZARD SERIOUS INJURY OR DEATH CAN RESULT OIL LEAKS WILL DAMAGE CARPET PAINT OR OTHER SURFACES IN VEHICLES OR TRAILERS A02231 HOW TO PREVENT IT ALWAYS PLACE COMPRESSOR ON A PROTECTIVE MAT WHEN TRANSPORTING TO PROTECT AGAINST DAMAGE TO VEHICLE FROM LEAKS REMOVE COMPRESSOR FROM VEHICLE IMMEDIATELY UPON ARRIVAL AT YOUR DESTINATION 6 ENG HAZARD RISK OF UNSAFE OPERATION WHAT CAN HAPPEN UNSAFE OPERATION OF YOUR AIR COMPRESSOR COULD LEAD TO SERIOUS IN JURY OR DEATH TO YOU OR OTHERS 7 ENG HOW TO PREVENT IT REVIEW AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS IN THIS MANUAL BECOME FAMILIAR WITH THE OPERATION AND CONTROLS OF THE AIR COMPRESSOR KEEP OPERATING AREA CLEAR OF ALL PERSONS PETS AND OBSTACLES KEEP CHILDREN AWAY FROM THE AIR COMPRESSOR AT ALL TIMES DO NOT OPERATE THE PRODUCT WHEN FATIGUED OR UNDER THE INFLUENCE OF ALCOHOL OR DRUGS STAY ALERT AT ALL TIMES NEVER DEFEAT THE SAFETY FEATURES
12. Instruction manual Model CPLDC2540P To learn more about Porter Cable visit our website at http www porter cable com PORTER CABLE PROFESSIONAL POWER TOOLS Copyright 2004 Porter Cable Corporation ESPANOL PAGINA 25 FRANCAIS PAGE 49 Direct Drive Oil Lube Portable Air Compressor JETSTREAM IMPORTANT Please make certain that the person who is to use this equipment carefully reads and understands these instructions before starting operations The Model and Serial No plate is located on the frame Record these numbers in the spaces below and retain for future reference Model No Type Serial No Part No A02231 041 0 SAFETY GUIDELINES DEFINITIONS This manual contains information that is important for you to know and understand This information relates to protecting YOUR SAFETY and PREVENTING EQUIPMENT PROBLEMS To help you recognize this information we use the symbols below Please read the manual and pay attention to these sections PNY NTG 3 0 dicates an UNG nile gn dicates a potentially imminently hazardous hazardous situation situation which if not avoided will which if not avoided may result in result in death or serious injury minor or moderate injury IMG ice ndicates a potentially Pearle Used without the hazardous situation safety alert symbol which if not avoided could result in indicates a potentially hazardous death or serious injury situation
13. NSTALLATION HOW TO SET UP YOUR UNIT Location of the Air Compressor Locate the air compressor a clean dry and well ventilated area The air compressor should be located at least 12 away from the wall or other obstructions that will interfere with the flow of air The air filter must be kept clear of obstructions which could reduce air flow to the air compressor The air compressor requires fresh air flow for proper cooling DO NOT ALLOW THE COMPRESSOR TO GET WET GROUNDING INSTRUCTIONS RISK OF ELECTRICAL SHOCK In the event of a short AWARNING circuit grounding reduces the risk of shock by providing an escape wire for the electric current This air compressor must be properly grounded The portable air compressor is equipped with a cord having a grounding wire with an appropriate grounding plug see following illustrations 1 The cord set and plug with this unit contains a grounding pin This plug MUST be used with a grounded outlet IMPORTANT The outlet being used must be installed and grounded in accordance with all local codes and ordinances 2 Make sure the outlet being used has Plug the same configuration as the grounded plug DO NOT USE AN 02 ADAPTER See illustration Grounded i Outlets 3 Inspect the plug and cord before each 13 use Do not use if there signs of damage Grounding Pin 4 If these grounding instructions are not completely understood or i
14. Pressure reading on the regulated pressure gauge if equipped drops when an accessory is used Air leak from safety valve Compressor is not supplying enough air to operate accessories Restricted air intake Regulator knob has continuous air leak Regulator will not shut off air outlet It is normal for some pressure drop to occur Possible defect in safety valve Prolonged excessive use of air Compressor is not large enough for air requirement Hole in hose Check valve restricted Air leaks Restricted air intake filter Dirty air filter Damaged regulator Damaged regulator 21 ENG CORRECTION If there is an excessive amount of pressure drop when the accessory is used adjust the regulator as instructed in the Operation section NOTE Adjust the regulated pressure under flow conditions while accessory is being used Operate safety valve manually by pulling on ring If valve still leaks it should be replaced Decrease amount of air usage Check the accessory air requirement If it is higher than the SCFM or pressure supplied by your air compressor you need a larger compressor Check and replace if required Remove and clean or replace Tighten fittings Clean or replace air intake filter Do not operate the air compressor with the filter removed Refer to the Air Filter paragraph in the Maintenance section Clean or replace See Air Filte
15. Release safety valve ring 15 ENG A02231 5 Drain water from air tank by opening drain valve counter clockwise on bottom of tank Water will condense in the air tank If not drained water AWARNING will corrode and weaken the air tank causing a risk of air tank rupture 6 After the water has been drained close the drain valve clockwise The air compressor can now be stored NOTE If drain valve is plugged release all air pressure The valve can then be removed cleaned then reinstalled Oil AWARNING Drain tank to release air pressure before removing the dipstick or oil drain plug AWARNING head and cylinder sleeve are very hot Do not ouch Checking 1 Set the On Auto Off lever to OFF 2 Remove dipstick A and check oil on dipstick for visual signs of contaminants water dirt etc Make sure air vent C in dipstick is free from debris If air vent is blocked pressure can build in crankcase causing damage to air compressor and possible personal injury 3 Wipe oil from dipstick 4 Replace dipstick and allow oil to collect on dipstick 5 Remove dipstick and check oil level on dipstick mark indicates full and Full the mark indicates add oil If oil level is below mark slowly add oil until it P reaches the full mark on the dipstick NOTE Use a air compressor oil such as SAE 30 API CG CD heavy duty motor oil Under extreme winter conditions use SA
16. SSURE YOU MUST INSTALL A PRESSURE REGULATOR AND PRESSURE GAUGE TO THE AIR OUTLET IF NOT EQUIPPED OF YOUR COMPRESSOR FOLLOW THE EQUIPMENT MANUFACTURERS RECOMMENDATION AND NEVER EXCEED THE MAXIMUM ALLOWABLE PRESSURE RATING OF ATTACHMENTS NEVER USE COMPRESSOR TO INFLATE SMALL LOW PRESSURE OBJECTS SUCH AS CHILDREN S TOYS FOOTBALLS BASKETBALLS ETC HAZARD RISK FROM FLYING OBJECTS WHAT CAN HAPPEN THE COMPRESSED AIR STREAM CAN CAUSE SOFT TISSUE DAMAGE TO EXPOSED SKIN AND CAN PROPEL DIRT CHIPS LOOSE PARTICLES AND SMALL OBJECTS AT HIGH SPEED RESULTING IN PROPERTY DAMAGE OR PERSONAL INJURY A02231 HOW TO PREVENT IT ALWAYS WEAR ANSI 287 1 APPROVED SAFETY GLASSES WITH SIDE SHIELDS WHEN USING THE COMPRESSOR NEVER POINT ANY NOZZLE OR SPRAYER TOWARD ANY PART OF THE BODY OR AT OTHER PEOPLE OR ANIMALS ALWAYS TURN THE COMPRESSOR OFF AND BLEED PRESSURE FROM THE AIR HOSE AND TANK BEFORE ATTEMPTING MAINTENANCE ATTACHING TOOLS OR ACCESSORIES 4 ENG HAZARD RISK OF ELECTRICAL SHOCK WHAT CAN HAPPEN YOUR AIR COMPRESSOR IS POWERED BY ELECTRICITY LIKE ANY OTHER ELECTRICALLY POWERED DEVICE IF IT IS NOT USED PROPERLY IT MAY CAUSE ELECTRIC SHOCK REPAIRS ATTEMPTED BY UNQUALIFIED PERSONNEL CAN RESULT IN SERIOUS INJURY OR DEATH BY ELECTROCUTION ELECTRICAL GROUNDING FAILURE TO PROVIDE ADEQUATE GROUNDING TO THIS PRODUCT COULD RESULT IN SERIOUS HOW TO PREVENT IT NEVER OPERATE THE COMPRESSOR
17. connect the other electrical appliances from circuit or operate the compressor on its own branch circuit PROBLEM Knocking Noise Possible defect in safety Squealing sound valve Defective check valve Compressor mounting screws loose Carbon build up in pump Compressor pump has no oil 23 ENG CORRECTION Operate safety valve manually by pulling on ring If valve still leaks it should be replaced Contact a Trained Service Technician Tighten mounting screws see Parts manual for torque specifications Have checked by a Trained Service Technician See Oil Checking paragraph in the Maintenance section A02231 LIMITED WARRANTY PORTER CABLE CORPORATION warrants to the original purchaser that all products covered under this warranty are free from defects in material and workmanship Products covered under this warranty include air compressors air tools service parts pressure washers and generators which have the following warranty periods 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 Limi
18. en the motor is running or continuous leaking after unit reaches cut out pressure How to Use Your Unit How to Stop 1 Set the On Auto Off lever to OFF Before Starting Break in Procedure AWARNING Serious damage may result if the following break in instructions are not closely followed This procedure is required before the air compressor is put into service and when the check valve or a complete compressor pump has been replaced 1 Make sure the On Auto Off lever is in the OFF position 2 Check oil level in pump See Oil paragraph in the Maintenance section for instructions NOTE Pull coupler back until it clicks to prevent air from escaping through the quick connect 13 ENG A02231 Plug the power cord into the correct branch circuit receptacle Refer to Voltage and Circuit Protection paragraph in the Installation section of this manual Open the drain valve fully counter clockwise to permit air to escape and prevent air pressure build up in the air tank during the break in period Move the On Auto Off lever to ON AUTO position The compressor will start Run the compressor for 20 minutes Make sure the drain valve is open and there is minimal air pressure build up in tank After 20 minutes close the drain valve clockwise The air receiver will fill to cut out pressure and the motor will stop The compressor is now ready for use Before Each Start Up 1 2
19. f in doubt as to whether the compressor is properly grounded have the installation checked by a qualified electrician AWARNING GROUNDING CAN RESULT IN ELECTRICAL Do not modify the plug provided If it does not fit the available outlet a correct outlet should be installed by a qualified electrician Repairs to the cord set or plug MUST be made by a qualified electrician A02231 10 ENG Extension Cords Use extra air hose instead of an extension cord to avoid voltage drop and power loss to the motor and to prevent overheating If an extension cord must be used be sure it is e a3 wire extension cord that has 3 blade grounding plug and a 3 slot receptacle that will accept the plug on the product e in good condition e longer than 50 feet e 12 gauge AWG or larger Wire size increases as gauge number decreases 10 AWG and 8 AWG may also be used DO NOT USE 14 OR 16 AWG Voltage and Circuit Protection Refer to the Parts Manual for the voltage and minimum branch circuit requirements Certain air compressors can be operated on a 15 amp circuit if the following conditions are met 1 Voltage supply through branch circuit is 15 amps 2 Circuit is not used to supply any other electrical needs lights appliances etc Extension cords comply with specifications Circuit is equipped with a 15 amp circuit breaker or 15 amp time delay fuse NOTE If compressor is connected to a circuit protected by fuses u
20. ge The outlet pressure gauge indicates the air pressure available at the outlet side of the regulator This pressure is controlled by the regulator and is always less than or equal to the tank pressure Tank Pressure Gauge The tank pressure gauge indicates the reserve air pressure in the tank Regulator Controls the air pressure shown on the outlet pressure gauge Pull the knob out and turn clockwise to increase pressure and counterclockwise to decrease pressure When the desired pressure is reached push knob in to lock in place Universal Quick Connect Body The universal quick connect body accepts the three most popular styles of quick connect plugs Industrial automotive Tru flate and ARO One hand push to connect operation makes connections simple and easy Drain Valve The drain valve is located at the base of the air tank and is used to drain condensation at the end of each use Cooling System not shown This compressor contains an advanced design cooling system At the heart of this cooling system is an engineered fan It is perfectly normal for this fan to blow air over the pump head cylinder sleeve and crankcase You know the cooling system is working when air is being expelled Air Compressor Pump not shown Compresses air into the air tank Working air is not available until the compressor has raised the air tank pressure above that required at the air outlet A02231 12 ENG Dipstick Indicates
21. o Add Oil To Pump DO NOT ATTEMPT TO OPERATE THIS AIR A CAUTION COMPRESSOR WITHOUT FIRST ADDING OIL TO THE CRANKCASE Serious damage can result from even limited operation unless filled with oil and broken in correctly Make sure to closely follow initial start up procedures COMPRESSORS ARE SHIPPED WITHOUT OIL A small A CAUTION amount of oil may be present in the pump upon receipt of the air compressor This is due to plant testing and does not mean the pump contains oil Multi Viscosity motor oils like 10W 30 should not be A CAUTION used in an air compressor They leave carbon deposits on critical components thus reducing performance and compressor life Use air compressor oil only NOTE Use an air compressor oil such as SAE 30 API CG CD heavy duty motor oil Under extreme winter conditions use SAE 10 weight oil 1 Place unit on a level surface Drain tank to release AWARNING air pressure before removing the dipstick Make sure air vent B AWARNING in dipstick is free from debris If air vent is blocked pressure can build in crankcase causing damage to air compressor and possible personal injury Full 2 Remove dipstick A and slowly fill Add crankcase with oil Crankcase capacity is 6 fluid ounces 177 4 ml Oil level should be at the full mark on the dipstick NOTE If the oil is added too quickly it will overflow and appear to be full 3 Replace dipstick 9 ENG A02231 I
22. ors 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 service call arrangements e If the purchaser does not receive satisfactory results from the Porter Cable Authorized Warranty Service Center the purchaser should contact Porter Cable THIS WARRANTY DOES NOT COVER e Merchandise sold as reconditioned used as rental equipment and floor or display models e 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 operate the product in accordance with the instructions provided in the Owners Manual s supplied with the product 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 50 during one hour period is considered misuse because the air compressor is undersized for the required air demand e 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 e 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
23. pumps air more than 50 of one hour is considered misuse because the air compressor is undersized for the required air demand Maximum compressor pumping time per hour is 30 minutes SPECIFICATIONS Model No CPLDC2540P Horsepower Peak 2 5 Bore 2 363 Stroke 890 Voltage Single Phase 120 Minimum Branch Circuit Requirement 15 amps Fuse Type Time Delay Air Tank Capacity Gallon 4 0 Approximate Cut in Pressure 120 PSIG Approximate Cut out Pressure 150 PSIG SCFM 40 PSIG 5 4 SCFM 90 PSIG 4 0 ACAUTION air compressor can be operated 15 amp circuit 1 Voltage supply to circuit is normal 2 Circuit is not used to supply any other electrical needs lights appliances etc 3 Extension cords comply with specifications in owners manual 4 Circuit is equipped with 15 amp circuit breaker or 15 amp time delay fuse If any of the above conditions cannot be met or if operation of the air compressor repeatedly causes interruption of the power it may be necessary to operate it from a 20 amp circuit It is not necessary to change the cord set A circuit breaker is preferred Use only a fuse or circuit breaker that is the same rating as the branch circuit on which the air compressor is operated If the air compressor is connected to a circuit protected by fuses use dual element time delay fuses A02231 8 ENG ACCESSORIES Accessories for this unit are available at the store the unit was purchased T
24. quick connect 8 Reassemble gauges and quick connect Orient gauges to read correctly Tighten quick connect with wrench A02231 18 ENG STORAGE Before you store the air compressor make sure you do the following 1 Review the Maintenance section the preceding pages and perform scheduled maintenance as necessary Set the On Auto Off lever to OFF Turn the regulator counterclockwise and set the outlet pressure to zero Remove the air tool or accessory oP Pull ring on safety valve allowing air to bleed from the tank until tank pressure is approximately 20 psi Release safety valve ring 6 Drain water from air tank by opening drain valve on bottom of tank A WARNING Water will condense in the air tank If not drained water will corrode and weaken the air tank causing 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 valve can then be removed cleaned then reinstalled 8 Protect the electrical cord and air hose from damage such as being stepped on or run over Wind them loosely around the compressor handle If so equipped Store the air compressor in a clean and dry location 19 ENG A02231 AWARNING PROBLEM CAUSE Excessive tank pressure safety valve pops off Air leaks at fittings Air leaks at or inside check valve Air leaks at pressure switch release valve
25. r paragraph in the Maintenance section Replace Replace A02231 PROBLEM Motor will not run A02231 Motor overload protection switch has tripped Tank pressure exceeds pressure switch cut in pressure Check valve stuck open Loose electrical connections Possible defective motor or starting capacitor Paint spray on internal motor parts Pressure release valve on pressure switch has not unloaded head pressure Fuse blown circuit breaker tripped 22 ENG CORRECTION Let motor cool off and overload switch will automatically reset Motor will start automatically when tank pressure drops below cut in pressure of pressure switch Contact a Trained Service Technician Check wiring connection inside pressure switch and terminal box area Have checked by a Trained Service Technician Have checked by a Trained Service Technician Do not operate the compressor in the paint spray area See flammable vapor warning Bleed the line by pushing the lever on the pressure switch to the off position if the valve does not open replace switch 1 Check fuse box for blown fuse and replace as necessary Reset circuit breaker Do not use a fuse or circuit breaker with higher rating than that specified for your particular branch circuit 2 Check for proper fuse You should use a time delay fuse 3 Check for low voltage conditions and or proper extension cord 4 Dis
26. rsonal injuries can occur Before performing any maintenance or repair disconnect power source from the compressor and bleed off all air pressure To ensure efficient operation and longer life of the air compressor outfit a routine maintenance schedule should be prepared and followed The following routine maintenance schedule is geared to an outfit in a normal working environment operating on a daily basis If necessary the schedule should be modified to suit the conditions under which your compressor is used The modifications will depend upon the hours of operation and the working environment Compressor outfits in an extremely dirty and or hostile environment will require a greater frequency of all maintenance checks NOTE See Operation section for the location of controls To Check Safety Valve AWARNING If the safety valve does not work properly over pressurization may occur causing air tank rupture or an explosion 1 Before starting compressor pull the ring on the safety valve to make sure that the safety valve operates freely If the valve is stuck or does not operate smoothly it must be replaced with the same type of valve To Drain Tank 1 Set the On Auto Off lever to OFF 2 Pull the regulator knob out and turn clockwise to set the outlet pressure to zero 3 Remove the air tool or accessory 4 Pull ring on safety valve allowing air to bleed from the tank until tank pressure is approximately 20 psi
27. sanding disks or pads saw and shear 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 of another company such as gasoline engines The product manufacturer s warranty if any will apply ANY INCIDENTAL INDIRECT OR CONSEQUENTIAL LOSS DAMAGE OR EXPENSE THAT MAY RESULT FROM ANY DEFECT FAILURE OR MALFUNCTION OF THE PRODUCT IS NOT COVERED BY THIS WARRANTY Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you IMPLIED WARRANTIES INCLUDING THOSE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR 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 may not apply to you Porter Cable Corporation Jackson TN USA 1 888 559 8550
28. se only time delay fuses Time delay fuses should be marked D in Canada and T in the US If any of the above conditions cannot be met or if operation of the compressor repeatedly causes interruption of the power it may be necessary to operate it from a 20 amp circuit It is not necessary to change the cord set 11 ENG A02231 OPERATION 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 with the location of various controls and adjustments Save this manual for future reference Description of Operation Become familiar with these controls before operating the unit On Auto Off Switch Turn this switch Tank R ON to provide automatic power to the ig 2 pressure Pressure pressure switch and OFF to remove power at the end of each use Pressure Switch The pressure switch automatically starts the motor when the air tank pressure drops below the factory set cut in pressure It stops the Gauge motor when the air tank pressure On Auto Oft reaches the factory set cut out Switch pressure Safety Valve If the pressure switch does not shut off the air compressor at its cut out pressure setting the safety valve will protect against high pressure by popping out at its factory set pressure slightly higher than the pressure switch cut out setting Outlet Pressure Gau
29. tarting The compressor will automatically restart after the motor cools If the overload protector shuts the motor off frequently check for a possible voltage problem Low voltage can also be suspected when 1 The motor does not get up to full power or speed 2 Fuses blow out when starting the motor lights dim and remain dim when motor is started and is running 17 ENG A02231 SERVICE AND ADJUSTMENTS AWARNING Unit cycles automatically when power is on When doing Maintenance you may be exposed to voltage sources compressed air or moving parts Personal injuries can occur Before performing any Maintenance or repair unplug the compressor and bleed off all air pressure ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE PERFORMED BY TRAINED SERVICE TECHNICIAN AWARNING Before servicing Unplug or disconnect electrical supply to the air compressor Bleed tank of pressure Allow the air compressor to cool To Replace Regulator 1 Release all air pressure from air tank See To Drain Tank in the Maintenance section Unplug outfit wo Using an adjustable wrench remove the gauges and quick connect from the regulator 4 Remove the regulator 5 Apply pipe sealant tape to the nipple on the pressure switch 6 Assemble the regulator and orient as shown NOTE Arrow indicates flow of air Make sure it is pointing in the direction of air flow Regulator 7 Reapply pipe sealant to gauges and
30. ted warranty on pressure washers used in consumer applications i e personal residential household 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 failed within the warranty period Service will be scheduled according to the normal work flow and business hours 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 to state RESPONSIBILITY OF ORIGINAL PURCHASER initial User process a warranty claim on this product DO NOT return it to the retailer The product must be evaluated by an 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 e Retain original cash register sales receipt as proof of purchase for warranty work e 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 compress
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